STATEMENT OF TECHNICAL REQUIREMENTS

FOR

ONLINE/ OFFLINE/ 24 VOLT BATTERY BACK-UP

UPS SYSTEM

EED-50-XX

Jan 19

MATERIAL BRANCH
DIRECTORATE OF ELECTRICAL ENGINEERING
INTEGRATED HEADQUARTERS
MOD (NAVY)
‘D-II’ WING, SENA BHAWAN
NEW DELHI 110011

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 Record of Amendments

Sl.No Amendment Authority Date Signature

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Revision Note: - Nil

Historical Record: -Nil

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 CONDITIONS OF RELEASE

1. This EED Specification has been prepared for the use of the Indian Navy and of
its contractors in the execution of contracts for supply of Online/ Offline/ 24 Volt
BatteryBack-up UPS Systems to the Indian Navy.

2. This document is a Copyright of the Indian Navy. The information contained in

this document is not to be released, reproduced or published without written permission
of the Integrated Headquarters Ministry of Defence (Navy).

3. Indian Navy reserves the right to amend or modify the contents of this
specification without consulting or informing any holder.

4. This specification may call for the use of processes, substances and procedures
that may be injurious to health, if adequate precautions are not taken. It refers only to
technical suitability and in no way absolves either the supplier or the user from statutory
obligations relating to health and safety at any stage of manufacture or use.

5. Where attention is drawn to hazards, those quoted may not necessarily

beexhaustive.

6. These specifications are the property of the Indian Navy and unless otherwise
authorised in writing by the Naval Headquarters, must be returned on completion of the
contract or submission of the tender, in connection with which it is issued.

7. When the specification is issued in connection with a tender or contract, the user
should ensure that he is in possession of the correct version of documents relevant to
the particular tender or contract. Inquiries in this connection may be made from IHQ
MoD(N), Sena Bhawan, New Delhi. Tele (011) 23010798, Fax: 011-23011212.

8. Unless otherwise specified, reference in this specification to any document

means the latest version of the document and all amendments promulgated thereafter.

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 CONTROL SHEET

Title EED-50-XX

Online/ Offline/ 24 VoltBattery Back-upUPS Systems

No. of
58
Pages

(a) Cdr Vinay Bagi, Cdr(EE)

(b) Lt Cdr Shreesh Dandekar, Lt Cdr (EE)

Prepared
by (c) Mr Gautam Ghosh, JDO (L)

(d) Mr G Srinivasulu, SDM(L)

Checked
Capt Vivek Sharma, Capt (EE)
by

Approved
Cmde Indrajit Dasgupta, Cmde(EE)
by
(a) IHQ MoD (N) {DPRO, DLS, DSP,DND, DQA (N), DQA (WP)
DSSD (for ATV HQ)}

(b) Command Headquarters (WNC/ENC/SNC/ANC)

(c) ND(Mbi/V)

(d) DMDE, Secunderabad

Distributio
(e) NSRY (K/PB/Karwar)
n
(f) MO (Mbi/V/Kar)

(g) M/s HSL, Visakhapatnam

(h) M/s GRSE, Kolkata

(j) M/s MDSL, Mumbai

(k) M/s GSL, Goa

3
 CONTENTS

Ser Chapter Page No

1. Chapter-I Introduction 6

2. General Requirements 10

3. Online UPS 11
Chapter-II
4. Offline UPS 13

5. 24 Volt DC Backup 15

Chapter-III
6. Technical & Design Requirements 17

Chapter-IV
7. Batteries 25

Chapter-V
8. Testing & Acceptance 27

LIST OF APPENDICES

Ser Appendix Page No

1. Appendix-A – Summary of Applicable Standards and 31

Specifications

2. Appendix-B – General Standards and Specifications 33

Power Supply

3. Appendix-C – General Standards and Specifications 35

Reliability and Maintainability

4. Appendix-D – General Standards and Specifications 36

Quality Assurance/ Control

4
5. Appendix-E – General Standards and Specifications 43
EMI/ EMC Considerations

6. Appendix-F – General Standards and Specifications 44

Supplier’s scope of system supply

7. Appendix-G – General Standards and Specifications 51

Product Support

8. Annexure to Appendix ‘D’ – Generic QAP for 53

Transformer

5
 CHAPTER-I

INTRODUCTION

1. This EED covers the design, manufacture, testing, onboard commissioning and
product support requirements of Online/ Offline/ 24 V Back-up UPS systems to be fitted
onboard Indian Naval Warships and other Naval ships/ crafts. Any deviation from these
specifications would be considered only with prior approval ofIHQ MoD(N)/ DEE.
Consideration to departure from the specification will be given when difficulties are
encountered during construction.

2. End User Requirement. The Ruggedised UPS designed and manufactured as

per specifications brought out in the subsequent paragraphs would be used onboard IN
warships for critical navigation, communication, propulsion controls and software
embedded systems to prevent power supply interruption to the systems during non-
availability/ interruption of primary supply.

3. Applicability of EED. This EED will be applicable to all new procurements for
new construction ships where the build specs specifically mentions this EED. It is also
applicable for already commissioned ships undertaking procurement of UPS for fitment
onboard. However, this EED will not be applicable to any existing orders or any repeat
orders for ongoing / existing contracts which are being progressed as per the earlier
promulgated Purchase Order Technical Specification of UPS systems.

4. Scope of EED. While every effort has been made to ensure the completeness of
the list, vendors are cautioned that they are obliged to meet all specified requirements
of the documents and standards cited in this EEDs. The design and technical
requirements of UPS, Standards and Specifications, Quality Assurance, Installation/
Training, Maintenance and Product Support have been elucidated in subsequent
Chapters.

5. Order of Precedence. Unless otherwise noted in the contract, in the event of a

conflict between the text of this document and the references cited herein, the text of
this document takes precedence. Nothing in this document, however, supersedes
applicable laws and regulations unless a specific exemption has been obtained.

6. Standards. The Standardsto be referred for design, manufacturing and testing

of UPS are specified at Appendix ‘A’.

7. Tests - Acceptance. The tests prior to acceptance of UPS are to be carried

out in the presence of IN nominated reps. The following tests details of which are
explained in Chapter IV, would be conducted: -

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 (a) Type Tests.

(b) Routine Tests.

(c) Investigation Tests.

(d) Acceptance Tests.

8. Power Supply. General Standards & Specification of Power Supply have been
indicated at Appendix ‘B’.

9. Reliability & Maintainability. Requirement of reliability and maintainability

have been indicated at Appendix ‘C’.

10. Quality Assurance & Control. Guidelines for Quality Assurance & Quality
control have been indicated at Appendix ‘D’.

11. EMI/ EMC. Requirement of Electromagnetic Interference (EMI)/

Electromagnetic Compatibility (EMC) have been indicated in Appendix ‘D’ &‘E’.

12. Scope of System Supply. Details on scope of supply have been indicated at
Appendix ‘F’.

13. Product Support. Requirement of Product support have been indicated at

Appendix ‘G’.

14. Acronyms. The following acronyms are included herein for ready reference and
are applicable for the purpose of this EED.

Ser Terms Expansion

(a) AC Alternating Current

(b) ATP Acceptance Test Procedure

(c) B&D Base & Depot

(d) BITE Built-in Test Equipment

(e) CoC Certificate of Conformity

(f) COTS Commercial Off The Shelf

(g) DC Direct Current

(h) DGQA Director General Quality Assurance

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 Ser Terms Expansion

(i) DI/DR Defect Identification/Defect Rectification

(j) DOI Directorate of Indigenisation

(k) DRDO Defence Research & Development Organisation

(l) DSP Directorate of Ship Production

(m) EED Electrical Engineering Department

(n) ELV Extra Low Voltage

(o) EMI/EMC Electromagnetic Interference / Electromagnetic

Compatibility

(p) ESD Electro Static Discharge

(q) ESS Electronic Stress Screening

(r) ET Environmental Tests

(s) FATs Factory Acceptance Trials

(t) HATs Harbour Acceptance Trials

(u) IEC International Electro-technical Commission

(v) IETM Interactive Electronic Technical Manual

(w) IGBT Insulated Gate Bipolar Transistor

(x) ILMS Integrated Logistics Management System

(y) INCAT Indian Naval Catalog of Inventory

(z) JSS Joint Service Specifications

(aa) LAN Local Area Network

(bb) LCD Liquid Crystal Display

(cc) LRU Line Replaceable Unit

(dd) LTE Limited Tender Enquiry

(ee) MO Material Organisation

(ff) MTBF Mean time Between Failure

(gg) MTTR Mean Time to Repair

(hh) MOV Metal Oxide Varistor

8
 Ser Terms Expansion

(ii) OBS Onboard Spares

(jj) OEM Original Equipment Manufacturer

(kk) OPA Order Placing Authority

(ll) PC Personal Computer

(mm) PCB Printed Circuit Board

(nn) PO Purchase Order

(oo) RFI Radio Frequency Interference

(pp) RFP Request For Proposal

(qq) QAP Quality Assurance Plan

(rr) QC Quality Control

(ss) SELV Safety Extra Low Voltage

(tt) SMF Sealed Maintenance Free

(uu) SPD Surge Protection Device

(vv) SOTRs Statement of Technical Requirements

(ww) STTE Special Testing Tuning Equipment

(xx) UPS Uninterruptible Power Supply

(yy) VRLA Valve Regulated Lead Acid

9
 CHAPTER-II

GENERAL REQUIREMENTS

1. Uninterruptible Power Supply (UPS) System. This is a device that has

an alternate source of energy (battery) that can provide power when the primary power
source is temporarily disabled. The function of an UPS for naval applications is to
supply uninterruptible power to the critical loads viz, vital alarm systems, navigation/
communication equipment, software embedded systems and control systems etc. for
usage onboard ships.

2. On the basis of working, the UPS System may be classified into following three
types:-

(a) Online or Double Conversion Technology.

(b) Offline or Standby Technology.
(c) 24 V DC Battery Backup Technology.

3. The type of UPS, i.e., Online/ Offline/ 24 V DC Battery Backup UPS, to be

supplied by the manufacturer would be specified by the User in the PO.

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 ONLINE UPS

Online - Double Conversion Technology

1. Description. An UPS using Online or Double Conversion Technology provides

the highest level of power protection available. The Online UPS converts the input AC
mains supply to DC power, which is then used to charge the battery. The DC current
flow is then fed through an inverter stage that reconstructs the AC mains output. Since
the AC output is completely regenerated, it is completely free from any mains-borne
interference such as spikes and voltage variations. The output voltage and frequency is
controlled precisely, thus ensuring a clean and stable sine wave power output. Online
UPS are able to withstand large fluctuations on the input voltage before transferring to
battery power, thus eliminating unnecessary battery discharges. Upon mains failure,
transfer to battery power is seamless. Online UPS also have various failsafe and self-
diagnostic features that instantly transfer the load onto mains power if there is a failure
within the UPS hardware, or if the UPS is overloaded.

Fig 1 - Online/ Double Conversion UPS Technology

2. Advantages. The advantages of Online UPS Technology are as follows:-

(a) Continuous & total power conditioning.

(b) Failsafe/overload protection with static bypass facility.
(c) No break on mains failure.
(d) Wide input voltage tolerance.

3. Disadvantages. The disadvantages are as follows:-

(a) Overall efficiency of UPS is reduced since inverter is always ON.

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 (b) The wattage of the rectifier is increased since it has to supply power to
inverter as well as charge battery.
(c) Online UPS is costlier than other Uninterruptible Power Supply systems.

4. General Requirements. The UPS system shall be an integrated system

comprising of input rectifier, high frequency based PWM technique inverter using IGBTs
and DSP/Microprocessor/Microcontroller based control electronics, static by pass switch
and manual bypass switch. The battery charger shall either be integral part of rectifier or
a separate module. The charger shall be designed such that it shall be able charge the
battery in constant voltage, constant current mode. The charger shall be capable to
recharge the battery from discharged condition to its full capacity in 8 hours. The UPS
system shall be of true double conversion with in-built isolation transformer (copper
wound) and shall be based on latest generation technology having proven performance
of satisfactory operation for similar applications. The inverter, rectifier and battery
charger shall be IGBT based systems with IGBT modules only. All components shall be
of quality and reliability that satisfies the requirements of a secure AC power to vital
equipment. Components shall be capable of withstanding the thermal and dynamic
stresses resulting from internal and external short circuits and circuit switching
operations etc. The design of the UPS shall be such as to withstand short circuit at load
without causing an adverse effect on the UPS. The vendor shall be responsible for
design, engineering and manufacturing of the complete system to fully meet the intent
and requirements of this specification.

5. Design & Performance. Incoming AC supplies shall be converted to DC

through input rectifier. The rectifier/charger shall operate according to the constant
voltage current limiting principle and shall incorporate a “Soft Start” feature to gradually
accept load on initial energizing. The UPS shall prevent power transients during
switching between Mains supply and Battery supply. UPS shall be designed to ensure
that the harmonic component in the input currents are limited to less than applicable
IEEE/IEC standards so as not to cause undue harmful effect on other sensitive
equipment operating on the same supply bus. Suitable filters/harmonic traps shall be
provided as required. An R.F. filter shall be provided at the input and output of UPS to
suppress the radio frequency interference to permissible limits as specified in IEC.
Transient/surge protection shall be provided in the input circuit to rectifiers to protect the
UPS from surges & voltage spikes. Class C type SPD of appropriate rating with
indication should be used. Suitable protection shall be provided in the control circuits to
guard against electrical oscillations which may be present in the input supply as caused
by DG sets.

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 OFFLINE UPS

Offline - Standby Technology

1. Description. During normal operation of an Offline UPS, the power flows

straight through the unit and hence only RFI filtering is provided. The UPS detects when
the input voltage fails or fluctuates outside a pre-set tolerance window (indicated at
Appendix ‘A’) and a relay closes, allowing the UPS to start feeding ‘UPS battery power’
via the inverter. The inverter is then switched ON and a square, step or sine waveform
output is supplied. Upon the return of mains power, the output is switched back onto the
mains and the inverter is turned OFF.

Fig 2 - Offline/ Standby UPS Technology

2. Advantages. The advantages of Offline UPS Technology are as follows:-

(a) Low cost.

(b) Silent operation when in standby.
(c) Efficient.

3. Disadvantages. The disadvantages of Offline UPS Technology are as follows:-

(a) Minimal power protection.

(b) Poor output voltage regulation.

4. General Requirement. The UPS system shall be an integrated system

comprising of high frequency based PWM technique inverter using IGBTs and

13
DSP/Microprocessor/Microcontroller based control electronics, static by pass switch and
manual bypass switch. The battery charger shall either be integral part of rectifier or a
separate module. The charger shall be designed such that it shall be able charge the
battery in constant voltage, constant current mode. The charger shall be capable to
recharge the battery from discharged condition to its full capacity in 8 hours.

5. Design & Performance. Transient/surge protection shall be provided in the

input circuit to rectifiers to protect the UPS from surges & voltage spikes. Class C type
SPD of appropriate rating with indication should be used. Suitable protection shall be
provided in the control circuits to guard against electrical oscillations which may be
present in the input supply as caused by DG sets. Typically, a break of 4-10 msec
observed during the transfer to and from the battery mode.

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 24 VOLT DC BACKUP

1. Description. This UPS arrangement is provisioned at an intermediate position of

the power supply chain for equipment. The battery backup provides the advantage of
avoiding an extra inverter circuit as found in the case of COTS Online/ Offline UPS and
has the best compliance to EMI/ EMC requirements. The UPS is a standalone unit with
batteries housed inside or outside the cabinet/console based on the load requirement.

Fig 3 – 24 Volt DC Backup

2. Advantages. The advantages of 24 V DC back up system are as follows:-

(a) Low cost.

(b) Silent operation when in standby.
(c) Efficient.
(d) No conversionary circuitry.

3. Disadvantages. The disadvantages of 24 V Technology are as follows:-

(a) Minimal power protection.

(b) No failsafe - UPS will drop the load if there is a high start-up current or
overload.

4. General Requirement. On failure of primary supply (115/ 230 V AC/ 24 DC) the
UPS to smoothly transfer load through the 24 V DC circuit. The battery charger shall be

15
integral part of the system. The charger shall be designed such that it shall be able
charge the batteries in constant voltage, constant current mode. The charger shall be
capable to recharge the battery from discharged condition to its full capacity in 8 hours.

5. Design & Performance. Suitable protection shall be provided in the control

circuits. Typically, a break of 4-10 msec observed during the transfer to and from the
battery mode.

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 CHAPTER-III

TECHNICAL & DESIGN REQUIREMENTS

1. Technical Specifications. The design should conform to technical and

operational design requirements listed below,as applicable. The manufacturer shall
furnish/submit full technical details of offer together with full descriptive literature and
technical particulars, wiring diagram and working diagrams of the equipment offered: -

(a) Networking & Monitoring Interface

(i) Type of UPS: Online / Offline/ 24V DC
(ii) Multifunction Touch screen LCD, status, and control console
(iii) Port for Communication with PC and LAN for Online Monitoring and
Management (to be indicated specifically by OPA as per requirement )
(iv) System Fault Monitoring Capacity

(v) Data logging facility

(b) Protections (with alarm) – audio/ visual

(i) Input Voltage (Under Voltage / Over Voltage)
(ii) Output Voltage (Under Voltage / Over Voltage)
(iii) Phase Reversal
(iv) Overload
(v) Over Temperature
(vi) Battery Over Charging (with Alarm)
(vii) Battery Over Temperature
(viii) Short circuit
(ix) Backfeed Protection
(x) Residual Earth Current
(xi) Transient/ Surge Protection at Input
(c) Indications and Alarms (audio/ visual) LCD Display
(i) UPS on batteries
(ii) Mains (normal/ abnormal)
(iii) UPS trip
(iv) UPS in bypass mode
(v) Battery disconnected
(vi) Battery voltage low
(vii) Earth fault
(viii) Charger fault
(ix) General faults
(x) Battery over-temperature
(xi) Alarms for AC input(s) failed

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 (xii) Overload and Over current
(xiii) Battery discharging mode
(xiv) Input Voltage (Indication in LCD Display)
(xv) Battery Over Charging ( Indication in LCD Display and alarm shall be
provided)
(xvi) Over temperature
(xvii) Output Voltage ( Under Voltage / Over Voltage)
(xviii) Battery Voltage High
(xix) Parameters on LCD Display& Analogue meter
(a) Input voltage, current, frequency
(b) DC Voltage, Battery charging/Discharging current
(c) Output voltage, currenty
(d) Bypass voltage, current, frequency
(e) Output KVA
(f) Output PF
(g) General Fault
(d) Indications and Alarms (audio/ visual) 24V DC Battery Back up
(i) UPS on batteries
(ii) Mains (normal/ abnormal)
(iii) UPS trip
(iv) Battery disconnected
(v) Battery voltage low
(vi) Earth fault
(vii) Charger fault
(viii) Battery over-temperature
(ix) Alarms for AC input(s) failed
(x) Battery discharging mode
(xi) Input Voltage (Indication in LCD Display)
(xii) Battery Over Charging ( Indication in LCD Display and alarm shall be
provided)
(xiii) Load on bypass
(xiv) Over temperature
(xv) Output Voltage ( Under Voltage / Over Voltage)
(xvi) Battery Voltage High
(xvii) Parameters on LCD Display& Analogue meter
(a) Input voltage, current, frequency
(b) DC Voltage, Battery charging/Discharging current
(c) Output voltage, current
(d) General Fault
(e) Additional Requirements
(i) Ventilation Self-Ventilated enclosures
(ii) Service lighting Yes

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 (iii) Acoustic noise i.a.w IEC 61672-1
(iv) Maintenance Bypass Yes, Manual and Auto
(v) Ingress Protection (including IP 43
Enclosure for Battery pack)
(vi) Material used for frames /Doors Stainless Steel /Aluminum

2. Construction. The UPS Systems should meet the Ingress Protection as

specified in the technical specification. The fixture enclosure should be of Aluminum or
Steel (minimum SWG 14) with ventilation arrangements and having suitable
arrangements for mounting onboard ships. The UPS systems will be modular in design
with sufficient spatial isolation between the internal components. UPS system shall be
suitable for either floating output or earthed neutral, or earthing of star point, in case of
single phase/three phase system respectively. The terminal box/ distribution unit of UPS
supply should have a spare connector point for redundancy/ additional use.

3. Design Specifications. The UPS shall supply for vital equipment with
continuous uninterrupted power during a loss of ships power for minimum period of 30
minutes. Battery charging circuits shall be capable of recharging the battery from
discharged condition within 8 hrs. They shall be protected from undercharge and
overcharge. Battery charging shall be automatic and shall not affect normal unit
operation. The following is to be separately included, as applicable: -

(a) Facility shall be provided to automatically initiate transfer of the load from
inverters to the bypass supply and from bypass supply to the inverters in case of
Online UPS.

(b) All Isolator/breakers shall be adequately rated for continuous rating as well
as breaking capacity as applicable. All output isolating devices shall be double
pole type.

(c) All the thyristors, diodes, IGBTs and other electronic devices of UPS shall
be given adequate protection from short circuits.

(d) All PCBs shall be provided with a transparent epoxy coating for
environmental protection especially for tropical enviornment. They shall be
suitably located away from heat sources. All electronic control and monitoring
printed circuit cards shall be suitable for easy replacement. Monitoring points
shall be provided with identification on each of the PCBs and the PCB shall be
firmly clamped in position so that vibration or long usage does not result in loose
contacts.

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(e) Provision shall be available through on/ off button which shall
electronically shut down the UPS by turning off the rectifier, inverter switch and
battery circuit breaker.

(f) Manual maintenance bypass isolator switch is required to be provided on

the UPS cabinet.Operatingthe maintenance bypass isolator switch will directly
connect the critical load to the input AC power source bypassing the rectifier,
inverter, battery unit without interruption to the load.

(g) Protection against Electric Shock and Energy Hazards.The standard

specifies two categories of requirements based on following principals for
protection against electric shock from energized parts.

(i) The operator is permitted to have access to: -

(aa) Bare parts in SELV circuits.

(ab) Bare parts in limited current circuits;
(ac) Insulation of wiring in ELV circuits under the conditions
specified in IEC 60950-1.

NOTE Attention should be given access to bare conductive parts at

a voltage level of 25-50 V AC and 60-120 V DC.

(ii) The operator shall be prevented from having access to: -

(aa) Bare parts of circuits at ELV or hazardous voltages,

(ab) Operational or basic insulation of such parts
(ac) Unearthed conductive parts separated from parts at ELV or
at hazardous voltages by operational or basic insulation only.

(h) Protective Earthing. Accessible conductive parts of Class I equipment,

which might assume a hazardous voltage in the event of a single insulation fault,
shall be reliably connected to a protective earthing terminal within the equipment.
This requirement does not apply to accessible conductive parts that are
separated from parts at hazardous voltage by earthed metal parts, or solid
insulation or an air gap, or a combination of the two, meeting the requirements
for double insulation or reinforced insulation. In this case, the parts involved shall
be so fixed and so rigid that the minimum distances are maintained during the
application of force as required by the relevant tests of IEC 60950-1.

Note. Compliance is checked by inspection and by the applicable requirements

of IEC 60950-1.

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(i) Disconnect Devices. Disconnection devices shall be provided to
disconnect the UPS from the AC supplies for servicing by qualified personnel.
Unless required for functional use, the means of isolation can be located either in
the service access area or external to the equipment. For 3-Phase UPS, the
disconnect device shall disconnect simultaneously all phase conductors of the
supply. Where the disconnect device is a switch incorporated in the equipment,
its "ON" and "OFF".

(j) Protection Requirements.

(i) Protection against excess currents, short circuits and earth faults in
input and output circuits shall be provided as an integral part of the
equipment. Towards Battery circuit protection, a battery supply circuit shall
be provided with over-current protection. Where the batteries are installed
inside the UPS, the battery supply circuit shall be provided with a
protective device located adjacent to the battery connecting means before
any component which may fail short-circuited, such as capacitors, semi-
conductors, or similar components.

(ii) Charging Voltages. Batteries shall be protected against excessive

voltages under any single fault condition, for example, due to a charger
failure, by switching off the charger or interrupting the charging current.
The charging voltage limits shall be as declared by the manufacturer.
Compliance is checked by circuit evaluation and a performance test.

(k) Operator Protection. To areas where operators have access, the

provisions of IEC 60950-1 safety interlocks, apply. Additionally, the following sub-
clauses apply to service persons who find it necessary to reach over, under,
across and around an un-insulated electrical part or moving part to make
adjustments or measurements while the UPS is energized.

(i) Covers. Parts at hazardous voltage or energy level shall be so

arranged and covers so located as to reduce the risk of electric shock or
high current levels while covers are being removed and replaced.

(ii) Location and guarding of parts. Parts at hazardous voltage or

energy level and moving parts that involve a risk of injury to persons shall
be located, guarded or enclosed so as to reduce the likelihood of
unintentional contact by a service person adjusting controls or performing
mechanical functions with the UPS energized.

21
(iii) Parts on Doors. Parts at hazardous voltage, located on the rear
side of a door, shall be guarded or insulated to reduce the likelihood of
unintentional contact of the live parts by a service person.

(iv) Component Access. A component that requires inspection or

maintenance while energized shall be so located and mounted with
respect to grounded metal parts that it is accessible for electrical service
functions without subjecting the service person to the risk of electric
shock, hazardous energy level, high current or injury to person by
adjacent moving parts. Access to a component shall not be impeded by
other components or wiring.

(v) Capacitor banks. Capacitor banks shall be fitted with a means of

discharge for protection of service persons. A warning label shall be
added if discharge time exceeds 10 s, stating the time taken to reduce the
hazard to a safe level (not greater than 5 min).

(vi) Internal batteries. Internal batteries shall be so arranged as to

minimize risk of electric shock from inadvertent contact with terminals and
the interconnection method shall be such as to minimize risk of short-
circuiting and electric shock during servicing and replacement.

(vii) Means of connection.

(aa) For safe and reliable connection to the primary power

supply, the UPS shall be provided with one of the following:-

(aaa) Terminals for permanent connection to the supply.

(aab) A non-detachable power supply cord for permanent

connection to the supply, or for connection to the supply by
means of a plug.

(aac) An appliance inlet for connection of a detachable

power supply cord.

(aad) Separate means of connection are provided for

different circuits.

(aae) Supply plug connections, if any, are not

interchangeable if a hazard could result from incorrect
attachment.

22
 (aaf) The operator is prevented from touching bare parts at
ELV or hazardous voltages, such as plug contacts, when
one or more connectors have been disconnected.

4. Controls. Following controls to be provided: -

(a) All the switches for starting, shut down and testing sequence.

(b) Primary input circuit breakers for feeding chargers, bypass line and DC
bus form battery including backup protection.

(c) Inverter ON/OFF switch (to initiate inverter operation).

(d) Emergency shut down switches on the panel.

5. Overall Dimensions and Weight. Overall dimensions and weight of the

equipment shall be kept to the minimum as possible.

6. Lifting Arrangement. Equipment weighing more than 40 kg shall be

provided with collar eyebolts or suitable lifting lugs. If the eyebolts cannot remain in situ
after the equipment has been installed in the ship, provision is to be made for their
securing arrangement on the equipment. Suitable handles must be provided in covers/
panels/doors for easy operation/ removal during maintenance.

7. Mounting Arrangement. The UPS shall be supplied with suitable base plate/
frame and shock mounts for fitment onboard (decks) ships.

8. Earthing. A separate earthing bolt will be provided on the fixtures to connect

it to the ship’s hull.

9. Tally Plate & Circuit Diagram Plate. Anodized Aluminum/brass tally plates as
stated below will be supplied along with the equipment as per NES 723:-

(a) Equipment Tally.

(b) Manufacturer Tally.
(c) Circuit Diagram Tally Plate.
(d) Switching ON/ OFF procedure.
(e) Safety Precautions.

23
10. Internal Wiring: LFH Cables are required to be used for all internal wirings as
per NES 526. All cables should be labeled with relevant markings to identify throughout
its length.

11. Insulation. Class ‘F’ or Higher rating.

10. Clearances & Creepage Distances. As per NES 609.

12. Safety. The following safety aspects to be catered: -

(a) Sharp edges/ corners on the enclosures/ doors/ covers should be avoided
to the safe handling/ operation/ usage.

(b) Safety arrangement should be provided for switches/ circuit breakers etc.,
which are susceptible to accidental activation.

(c) High voltage ares/ high current switching devices must be insulated or
guarded.

(d) Where ever, forced cooling is employed finger guards must be fixed to the
blowers / fans.

13. Components, Material and Finish. All components shall be of Naval

approved type for use on warships. Indication lamps used shall be of approved type.
Standard specification and grade of material of each component used shall be indicated
in the binding drawings. Make and type of components are to be listed in the binding
drawings. The quality of material and nature of finish shall confirm to specification NES-
507.

14. Terminals. Bolted type terminals and crimped lugs/ sockets of electrolytic
copper are to be provided for all incoming and outgoing cables. All terminals shall be
easily and safely accessible for connections as well as checking power supply voltage if
needed. Adequate spare terminal strips are to be provided for provision of additional
control and indication facilities. Adequate space is to be provided inside the equipment
for bending and termination of incoming & outgoing cables.

15. Painting. The painting shall be conforming to specification shade 632 of IS:5
(Powder coating) approved for marine application. The enclosure finish colour shall be
admiralty gray, semigloss.

16. Cable Glands. Compressible cable glands as per BS 6121/ EN 624440-

2013 (Equivalent cable glands also acceptable) are to be used.

24
 CHAPTER-IV

BATTERIES

1. SMF(Sealed Maintenance Free) VRLA Batteries with fire retardant enclosure/

cell, having testing reports (for 250Ah or maximum rating available with the firm) of
NABL approved laboratory of indigenous battery manufacturers.Batteries should not
emit gas during charging & discharging in normal operating conditions. Built-in batteries
are to be provided for UPS ratings up to 5 KVA and Batteries (type tested) for UPS
ratings beyond 5KVA are to be provided externally with fire proof/ fire retardant
enclosures. Rack should be designed to support easy replacement of individual
batteries. In case of a separate battery rack, it is required to meet specification as per
JSS 55555:2012 (Version (3.0) indicated in the document.

2. Terminals intended for connection to batteries shall indicate the polarity

according to IEC 60417/ IEC 61056 or be so constructed as to reduce the likelihood of
improper connection. Batteries are to be given adequate protection against electrolyte
spillage, such as electrolyte resistive coating of battery trays and cabinets. Battery cell/
enclosure should be of fire retardant material. Further, proper ventilation shall be
provided so that any potential explosive mixtures of hydrogen and oxygen are dispersed
safely below hazardous levels. External battery cabinets or battery compartments within
the UPS shall be provided with the following, clearly legible information in such a
position as to be immediately seen by a service person when servicing the UPS: -

(a) Battery type (Sealed maintenance free VRLA, Fire Retardant etc.) and
number of blocks or cells.

(b) Nominal voltage of total battery.

(c) Nominal capacity of total battery (optional).

(d) Warning label denoting an energy or electrical shock and chemical hazard
and reference to the maintenance handling and disposal requirements.

3. The rectifiers/ chargers shall be designed to completely re-charge the battery in a

maximum time of 8 hours after complete discharge. The rectifier/charger shall be sized
based on the maximum inverter input load when inverter is delivering its rated output at
0.8 pf lagging and recharge the battery to nominal rated capacity of the battery.

4. The rectifiers/charger shall sense the battery charging current and adjust the DC
bus voltage to maintain the charging current to pre-set level. A separate current limit
circuit shall also be provided for adjustment of battery current. Subsequent to a
discharge cycle when battery is connected to rectifier/charger, the battery current shall
be monitored, controlled and limited to set value automatically irrespective of the

25
inverter input current. The rectifier shall be protected against reverse battery connection
at dc link voltage.

5. Facility for initial charging/ discharging of batteries shall also be provided. The
rectifier/chargers shall be designed to completely charge the battery in a maximum time
of 8 hours after complete discharge.

6. The battery may be taken out of service for maintenance during which period it
shall be possible for the UPS to continue operation by drawing power from the rectifier.
Ripple content of the charger output shall not exceed 3% with battery connected.

26
 CHAPTER-V

TESTING AND ACCEPTANCE

1. Conditions for Tests. Equipment shall be tested by applying any condition

that may be expected in normal use and foreseeable misuse, with the UPS operating at
rated voltage or at the upper limit of the rated voltage range. Examples of normal use or
foreseeable misuse conditions are: -

(a) Any operation of accessible operating devices, such as knobs, levers,

keys and bars, that is not i.a.w. the manufacturer's instructions.

(b) Covering of groups of ventilating openings that are likely to be covered

simultaneously, for example, groups of openings situated on one side or on the
top of the equipment, such groups to be covered in turn.

(c) Operation under any output overload conditions, including a short circuit.

2. Loads for Tests. In determination of input current, and where other test results
could be affected, the following variables shall be considered and adjusted to give the
most unfavourable results:

(a) Loads due to recharging of batteries.

(b) Loads due to optional features, offered or provided for by the

manufacturer for inclusion in or with the equipment under test.

(c) Loads due to other units of equipment intended by the manufacturer to

draw power from the equipment under test.

(d) Loads that could be connected to any standard supply outlets in operator
access areas on the equipment.

(e) Artificial loads may be used to simulate such loads during testing.

3. Eligibility Criteria. The eligible vendor should have test certificates of UPS
systems conforming to type tests requirement indicated in this EED. In case the UPS
have not been type approved or the design/ material/technical specifications of the
equipment offered by the vendor have been changed/upgraded from the already type
approved item, the item would be subjected to type testing as per the requirement
specified in this EED. The firm should be in the field of manufacturing the UPS systems
and shall submit documentary evidence to this effect along with their offer.

27
4. Information to be supplied by the manufacturer. The manufacturer shall
submit the following information while offering for testing: -

(a) Details of foundations for equipment.

(b) Load data.

(c) Location etc. for various assembled equipment as may be needed.

(d) Complete layout dimensions for every unit/ all units with dimensions
required for erection purposes.

(e) Any other drawing/ information not specifically mentioned but considered
essential for installation of equipment.

5. Tests/ Trials/ Acceptance. Separate type, routine, acceptanceand

investigation tests for UPS shall beconducted.R-L load equivalent to the rated capacity
of the UPS in kVA with 0.8 pf shall bearranged at the manufacturers’ premises by the
manufacturer for the purpose oftesting. Various tests shall be performed by simulating
the combination of inductiveand resistive load of adequate capacity matching the rating
of the inverter. IN may conduct surprise check on manufacturing process and quality
controlalong with any of the test to ensure quality of product and its conformance to
Specifications. The equipment will be subjected to tests enumerated below: -

(a) Type Tests. Online/ Offline UPS is to be subjected to type testing, as per
Joint Services Specification JSS 55555:2012 (Version (3.0) and NES 1004. List
of tests is specified at Appendix ‘C’. Deficiencies, if any, observed during type
tests should be addressed and the tests to be repeated for satisfactory results.
Type test units shall be inspected/tested by IN at manufacturer’s premises or
where the type tests are arranged. Type tests shall be carried out on one UPS
unit of given design to verify that product to meet the requirements specified and
agreed upon between user and manufacturer. Subject to agreement between
user and manufacturer some or all the type tests shall be repeated whenever
required by IN or OPA on sample basis, so as to confirm the quality of the
product to meet the specified requirements. In addition, the manufacturer shall
repeat the type test to be witnessed by representative of IN or OPA either totally
or in part in following cases without any additional cost: -

(i) Modification of equipment likely to affect its function.

(ii) Failure or variations established during type or routine tests.

(iii) Resumption of production after an interruption of more than two

years.

28
 (d) At the time of indigenisation, if the firm is having TOT with foreign
Collaboration in consultation with OPA.

(e) In any other condition where IN/ OPA felt necessity of the type test.

(b) Routine Tests. These tests are to be carried out to verify that
properties of the product corresponding to those measured during prototype/type
tests. Routine tests are to be performed by the manufacturer on each equipment
and all the records of test results shall be maintained with traceability. The same
shall be produced before the IN inspecting officer/representative to verify the
routine test results. The UPS will undergo routine test as per approved QAP. The
subject routine tests are listed at Appendix C.

(c) Investigation Tests. Based on the performance, field experience, in

case of critical failures in the system or in view of the improvement measures,
investigation tests shall be carried out. These tests shall be specially requested
either by IN or user or by the manufacturer.

(d) Acceptance Tests. The acceptance tests are to be conducted in the

presence of IN nominated representative on the samples selected at random or
on all as agreed between OPA and manufacturer, to establish conformity of the
lot to be supplied with the requirements of the specification. OPA has the right to
insist acceptance tests on each unit in the presence of his nominated
representative.

6. Operational Conditions. The system devices/equipment should operate

satisfactory in the marine environmental (coastal conditions) and other operating
conditions as below: -

(a) Ambient Temperature: 0°C to +55°C.

(b) Relative Humidity: 30% to 100%.

7. Storage and Transportation. UPS equipment shall accept stationary storage

within a building and be transportable in its normal shipping container within following
ambient ranges i.a.w IS 16242 (Part 3): -

(a) Temperature: -25°C to +55°C.

(b) Relative Humidity: 20% to 95% (non-condensing).

29
8. Test Facilities. The Environmental Tests, ESS tests and EMI/EMC tests could
be conducted at any of the National accredited labs available in the country with
DRDO/DGQA and private sector. The details of the test facilities available i.e. ‘Weight’,
‘Chamber Dimensions’ and ‘Loading Capacity’ along with the postal address of the labs
have been promulgated by IHQ MoD(N)/ DOI vide ‘Compendium of Test Facilities’
document DI/DOC/03/2013. The document is available in public domain at http:\\www.
indiannavy.nic.in/link material branch/doi.

30
 Appendix ‘A’
(Refers to Para 6 of Chapter I)

SUMMARY OF APPLICABLE STANDARDS/ SPECIFICATIONS

Ser Particulars Reference Remarks

1. Internal Cabling NES 526

2. Internal Wiring Defence Standard 61-12 (Part

18)

3. Size of Gland NES 512

4. Cable Glands BS 6121/ EN 624440-2013

5. Creepage & Clearance NES 609

6. Size of tally plate and NES 723

letters for customized
units

7. Safety Markings on NES 784

units/ devices

8. Components, Material NES 507

& Finish

9. Surface Protection JSG 0457 - 01: 1986 Part I, Part

II, Part III and JSG 0457 -
01:1997 Part IV.

10. Shock and Dynamic JSS 55555:2012 (Version (3.0)

acceleration
specifications

11. Shock Standards JSS 55555:2012 (Version (3.0)

12. Shock Test for MIL STD 901D

Imported Equipment

13. Inclination/ Tilt CL 0563

14. EMI/EMC MIL-STD-461E/F

15. Seaway Conditions NES 1004

16. Environmental Testing JSS 55555:2012 (Version (3.0)

17. Environmental Stress 66301/Policy-07/DQA(N)/QA-07

31
Ser Particulars Reference Remarks

Screening dated 09 Aug 16 or latest

guidelines

18. ESD Protection IEC 61000-4-2

19. Documentation JSG 0251 & EED-S-048

20. IETM Level 4

21. Enclosure Protection IEC60529 (latest) IP 43

22. General and safety IS 16242 (Part 1): 2014

requirements for UPS

23. Electromagnetic IS 16242 (Part 2): 2014

Compatibility (EMC)
Requirements for UPS

24. Surge Test IEC 60000-4-5

25. Transient Test IEC 60000-4-4

26. Electrical Tests NES 511

27. Method of specifying

the Performance and
IS 16242 (Part 3): 2014
Test Requirements for
UPS

28. Electrical Safety

IEC 60950-1
Requirements

29. Battery Terminals IEC 60417

32
 Appendix ‘B’
(Refers to Para 8 of Chapter I)

GENERAL STANDARDS AND SPECIFICATIONS

POWER SUPPLY

1. Power Supply. The equipment will be supplied with ship’s main power
supply 380/415/440 V/ 230/115, 60/50Hz, 3Ф/ 1Ф as primary supply as indicated in
PO. Details of power supply requirements are indicated below: -

(a) Input Power Supply Characteristics

(i) 380/415/440 /220 V/115V (as per PO)
(ii) Average line to the value of 3 ± 10%
phase system
Voltage Line to line voltage of 1 ± 12%
phase of 3 phase system
(iii) Maximum unbalance 5%
(iv) Maximum modulation 2%
(v) 50/60 Hz (as per PO)
(vi) Load Range Tolerance ± 2%
Frequency
(vii) Constant Load Tolerance ± 1%
(viii) Modulation ± 0.25%
(ix) Maximum Individual 4%
Harmonic
Waveform
(x) Maximum Total Harmonic 8%
Content
(xi) Phase 3Ф/1Ф (as per PO)
(xii) Power Factor 0.8 or better
(b) InputTransients
(xiii) Ripple <1%
(xiv) Input voltage variation +10% to -15%, 1.0 sec
(xv) Regulation ±1%
(xvi) Input frequency variation ± 1.5%, 2.0 sec
(c) Output Power Supply Characteristics
(i) Voltage 380/415/440 /220 V/115V (as per PO)
(ii) Frequency 50/60 Hz (as per PO)
(iii) Phase 3Ф/1Ф (as per PO)
(iv) Load Power Factor 0.5 leading to 0.5 lagging (as per PO)
(v) Rated Power (KVA) 0.5, 1, 2, 3, 5, 7, 10, 15, 20
(vi) Efficiency at full load > 85% at nominal PF 0.8

33
(vii) Static Balanced ± 1%
(viii) Static Unbalanced ± 5%
Voltage Variation
(ix) Dynamic Load ± 4%
(x) Voltage Distortion <3%
(xi) Bypass Voltage Variation +5%
(xii) Frequency variation Mains synchronized in normal operation
50/60 Hz + 0.5% free running
(xiii) Back up time Minimum 30 minutes at rated full load
(xiv) Load Range Tolerance ± 4%
(xv) Constant Load Tolerance +1%
(xvi) Modulation 0.5%
(xvii) Bypass Frequency +1%
Variation
(xviii) Frequency Slew Rate 1 Hz/Sec
(xix) Crest Factor Better than 3:1
(xx) Remote Voltage ± 5%
Adjustment
(xxi) Over Load 150% for 1 min , 125% for 10 min
(xxii) Total Harmonic Distortion < 3% for linear load
< 5% for nonlinear load
(xxiii) Transfer time:
Sync mode < 4 msec
Un sync mode 4 - 10 msec
(xxiv) Phase displacement (for 3 With balanced load: 120° ± 1°
Ph output only) With 100% unbalanced load: 120° ± 3°

34
 Appendix ‘C’
(Refers to Para 9 of Chapter I)

GENERAL STANDARDS AND SPECIFICATIONS

RELIABILITY AND MAINTAINABILITY

1. System Performance.

(a) Design Review. The OEM is required to schedule formal design reviews
during the initial development (only for first time induction) of the system to
ensure that the user requirements and envisaged functionalities are captured
correctly at the design stage. The frequency of the design reviews will be
finalized during the contract conclusion.

(b) Reliability. The system design should be based on standard engineering

principles to provide a reliable product. The reliability figures in terms of MTBF /
MTTR shall be estimated by the OEM and submitted as part of the technical
proposal. The system performance will degrade gracefully in the event of a
failure. The system will contain no 'single point' control, whose
malfunctioning would result in a catastrophic failure.

(c) Maintainability. The built-in test equipment (BITE) if applicable will be

capable of detecting and localizing faults down to a single replaceable
PCB/Module.

2. MTBF/MTTR. System shall be designed for high MTBF (Mean Time Between
Failures) of greater than 10000 hours and low MTTR (Mean Time To Repair) of not
exceeding 60 minutes.

3. Commonality. The manufacturer to mention the level of commonality achieved

within the system at the following levels:-

(a) Module/sub module level.

(b) PCB level.
(c) Component level.

35
 Appendix ‘D’
(Refers to Para 10 of Chapter I)

GENERAL STANDARDS AND SPECIFICATIONS

QUALITY ASSURANCE/ CONTROL

1. Quality Assurance. The manufacturer should submit draft QAP (Quality

Assurance Programme) to the Directorate of Quality Assurance, Navy (DQAN) or
nominated QA agency (to be decided by the OPA). Mandatory inspections by the
inspection agency shall be listed in the QA Plan. The same would be approved by DQA
(N) taking into account the technical specifications, deliberations during the TNC/ CNC
and the PO. However, additional inspections may be called for by the inspection
authority when considered necessary. The manufacturer shall be responsible to provide
for and offer all inspection and testing facilities at manufacturer’s and sub-contractor’s
premises. The supplier is required to submit ATP document to ETMA (Mbi) for vetting
prior submission of same to OPA for approval at least 03 months prior acceptance. The
approving authority {IHQ MoD (N)} reserves the right to amend/ modify the QAP/ ATP
document. The approved QAP and ATP will form basis for inspection/ quality checks/
acceptance of items/ equipment. The equipment, including test battery set, supplied by
the vendor would be accepted subject to evaluation and clearance by inspection team.
However, the item should be of latest version conforming to current production standard
having 100% defined life at the time of delivery. In case of imported items, the
inspection of equipment would involve audit of CoCs/ test reports by inspection team
rep for applicable ET, EMI/ EMC & ESS specifications as per ATP and verifications of
internal QC undertaken by manufacturer at the OEM premises.

2. The QAP/ATP checks would be carried out by the Authorized Inspection Agency,
as appointed by the Indian Navy.

3. Inspection.

(a) Inspection Authority : DQA(N),West Block, RK Puram,Delhi-110066

(b) Inspecting Officer : Concerned Field Unit of DQA(N)
(c) Receipt Inspection : Shipyard / MOs
(d) Installation : Shipyard/Repair Yards with participation of OEM.
(e) Ship trials : As nominated by IHQ MoD(N)/ DEE.

4. Testing. The QAP will lay down the complete and detailed requirements of
QA activities and the methodology for acceptance of item/ equipment against the
particular supply order including Environmental Tests (ET) & EMI/ EMC tests, material
testing and Environmental Stress Screening (ESS) in any NABL/ Govt. approved Labs,

36
 Endurance (Burn-in) test etc. Conduct of all the tests and inspection in accordance with
QAP will be the responsibility of the supplier who is advised to identify the NABL/ Govt.
approved labs for undertaking such tests. These tests are enumerated as follows: -

(a) Environmental Tests (ET). The purpose of these tests is to check

the ability of the equipment to withstand prolonged environmental effects under
which the ruggedized UPS is likely to operate or stored. ET will be undertaken on
the first of the equipment. In case the test has been conducted on the equipment
earlier, the supplier will submit the test reports. ET, if already undertaken by the
firm against an earlier order, will only need to be repeated if design, manufacturing
process, vendor or any other specifications have been changed. The guidelines for
conducting ET for equipment have been promulgated vide JSS 55555-2012 (Rev
3) for indigenous equipment and MIL 810G/ equivalent for imported equipment.
The shock test for ruggedized UPS will be in accordance with NSS Grade II and
that for imported equipment will be MIL STD 901D. The detailed ET Plan for the
system indicating the device being subjected, test parameters, severities and
venue for conduct of the tests to be included in the QAP. Summary of the tests and
severities for Ruggedised UPS are as follows: -

ENVIRONMENTAL TEST SPECIFICATIONS

(In accordance with JSS 55555:2012 (Rev 3))

Test
Ser Test Specifications Remarks
No.

28 UPS installed in Major Warships The equipment

(Main Region)/ Submarines should be in
switched ‘ON’
± 0.125 mm constant
5 to 33 Hz condition during
displacement
the test.
UPS installed in Minor Warships
(Main Region) The equipment
(i) Vibration
would be
± 0.2 mm constant mounted on the
displacement vibration table by
Or its normal
7 to 300 Hz
± 30 mm/s constant means of
velocity (whichever is attachment on
the lesser) ship.

17 Procedure 6, Test condition K

Performance
High Operation : + 55°C
(ii) check during last
temperature Storage : + 70°C
hour
Duration : 24 Hrs

37
 10 Operating Temp : 40°C
RH : 95 %
Duration :
(iii) Damp heat
Unpacked and switched ‘OFF’: 15½ Hrs
Unpacked and switched ‘ON’: 30 min
Total duration : 16 Hrs

20 Procedure 4, Test condition H

Low
(iv) Temperature : - 10°C
Temperature
Duration : 16 Hrs

11 Duration : 15 min Equipment

should be
(v) Drip proof
operated during
the test

27 Test condition A : 7 cycles

Tropical Temperature : 20°C to 35°C
(vi)
Exposure RH : 95 %
Duration : 24 Hrs (one cycle)

21 To be conducted
Temperature : 30°C
Mould on
(vii) RH : > 90%
Growth representative
Duration : 28 days
samples

9 Procedure 2 To be conducted
Corrosion Temperature : 35°C on
(viii)
(Salt) RH : 90 to 95% representative
samples

NSS Grade II : 50g, 11ms (vertical)

(ix) Shock Test
22g, 11ms (lateral)

Note. Any deviation from the mentioned specifications will be brought to the notice of
IHQ MoD (Navy).

(b) Additionally, following Type Tests are required to be conducted on UPS: -

Specificatio
Ser Test Remarks
ns

(a) Roll- Max +30° with 8 sec

Seaway period
(i) NES 1004
conditions (b) Pitch- Max +10° with 20 sec
period

38
 (c) Heave- Max +4 m with 7 sec
period
(d) Yaw- Max 1.75° per s2
(e) Tilt (permanent)- Max 15° in
any direction
(f) List- Max 20° from vertical
(permanent)
(g) Trim- Max 5°

JSS 55555- 4000 ±10 bumps, 40g, 6msec, 1

(ii) Bump
Test 5 to 3 bumps /sec

CL 0563
(iii) Inclination/Tilt As per laid down specifications
Sec 19

As per Para 6.5.2.2 of IS: 16242

(iv) Free Fall Test
(Part 3): 2014.

Ingress
(v) Protection (IP IP 43
Rating)

IEC 60000-
(vi) Surge Tests 4-5 Class 2
(2KV)

IEC 60000-
Transient
(vii) 4-4 Class 2
Tests
(2KV)

Insulation Test
(viii) (with 100V NES 511
megger)

As per Para 6.5.3 of IS: 16242

(ix) Storage Test IS: 16242
(Part 3): 2014.

As per Para 6.5.5 of IS: 16242

(x) Acoustic Noise IS: 16242
(Part 3): 2014.

Dynamic
IS: 16242 As per Para 6.4.2.11 of IS 16242
(xi) Performance
(Part 3): 2014.
Test

(c) EMI/ EMC Tests. Ruggedised UPS (indigenous/ imported) is required to

comply with following EMI/ EMC Tests as per MIL STD 461 E/F. The supplier will
be required to formulate EMI/ EMC Test Plan (EMITP) post placement of order
for vetting by NEC (Mbi) and approval by IHQ MoD (N). The EMI/ EMC testing

39
 would be carried out by the vendor as per approved EMITP. Relevant test reports
are to be submitted for scrutiny of NEC (Mbi)/ IHQ MoD (N) for clearance which
will be one of the pre-requisites for dispatch of equipment to end consignee.
Further details on EMI/ EMC considerations are explained in Appendix ‘E’: -

(i) CE 101, CE 102

(ii) RE 101, RE 102

(iii) RS 101, RS 103

(f) CS 101, CS 114, CS 116

(d) Environmental Stress Screening (ESS) Test. ESS test is applied

on 100% of electrical and electronic items, modules and units/ system to identify
and eliminate defective, abnormal or marginal parts and manufacturing defects.
ESS is to be carried out as per the severities promulgated by DQA (N) vide letter
no. 66301/Policy-07/DQA(N)/QA-07 dated 09 Aug 16 or latest guidelines.

(e) Endurance (Burn-In) Test. Endurance (Burn-In) test would be

carried out on the integrated system as per guidelines promulgated by DQA (N)
vide letter no. 66301/Policy-10/DQA(N)/QA-10 dated 14 Jun 13.

5. Routine Tests. Routines tests shall be performed on each UPS to verify all
SOTRs requirements as per approved QAP:-

(a) Functional Checks to meet the specifications mentioned at Appendix ‘A’

i.a.w. IS 16242 (Pt 1, Pt 3): 2014.
(b) Light load and functional test as per Para 6.2.2.3 of IS: 16242 (Part 3):
2014.
(c) Insulation Resistance Test (with 100/ 500 V DC megger/ insulation tester)
as per NES 511 (> 20 MΩ).
(d) High Voltage test as per NES 511 (2KV for 1 minute).
(e) Physical inspection, Dimensions and Weight.
(f) Switching Over time between main and battery supplies.
(g) ESS and Burn-in Test.
(h) IP/Dust Test.
(i) Plating/Painting.
(k) Reverse Polarity Test.
(l) Surge Test.
(m) Transient Test.
(n) Dielectric Test.
(o) Full Load Test.
(p) No Load Test.

40
 (q) Load Regulation Test.
(r) Battery Backup Test.
(s) Output Short Circuit Test.
(t) Temperature Rise test.
(u) Earth Bonding test.
(v) Milli-volt drop test.
(w) AC Input Return as per Para 6.2.2.8 of IS: 16242 (Part 3): 2014.
(x) Transfer to bypass as per Para 6.2.2.9 of IS: 16242 (Part 3): 2014.
(y) Overload and in Fault clearing capability as per Para 6.4.2.10 of IS: 16242
(Part 3): 2014.
(z) Dynamic performance as per Para 6.4.2.11 of IS: 16242 (Part 3): 2014.

6. Site tests. On site performance tests to be conducted for multi module UPS
equipment as per Para 6.3 of IS: 16242 (Part 3): 2014.

7. Test Instrumentation. As per Para 6.1.1.2 of IS: 16242 (Part 3): 2014.

8. Test Loads. Load tests (to be specified in PO) are to be performed for UPS by
connecting loads to the UPS output to simulate actual load conditions or by connecting
the actual load when available, as follows: -

(a) Routine load tests.

(b) Linear load tests.

(c) Non-linear load tests.

9. QA Aspects of Transformer. Transformer is a vital unit of UPS. QA checks

of the Transformer needs would be undertaken iaw generic QAP (No.
DQAN/QAP/L/2008/375 dated 06 Nov 08) promulgated by DQAN. Copy of generic QAP
of Transformer is placed at Annexure.

10. Preservation & Packing. Preservation & Packing of the equipment, spares and
goods contracted is to be ensured against damage due to weather hazards during
storage and transportation by Land, Sea and Air. The sellers shall ensure that the
stores are packed as per the contractual specifications.

11. Setting to Work (STW). The supplier is required to furnish the details of tests
to be carried out on-board for carrying out tests by owner’s rep. The supplier is also
required to provide necessary representative (s) to assist during the following phases
(where ever necessary):-

(a) Onboard installation.

(b) Trials as per approved procedure.

41
12. Approval of Drawings. All types of drawings would be approved by the order
placing authority.

13. Approval of ATP/ FATs Procedure/ GRAQs/ Trial Schedules. Approval of

Trials/ test procedures related documents would be approved by order placing authority.

42
 Appendix ‘E’
(Refers to Para 11 of Chapter-I)

GENERAL STANDARDS AND SPECIFICATIONS

EMI / EMC CONSIDERATIONS

1. EMI/EMC Specifications. The entire system should have total electro-magnetic

compatibility with all shipboard equipment. EMI/EMC checks are to be undertaken as
per MIL STD 461 ‘E/F’. The OEM/Vendor would be required to submit draft EMI/EMC
test plan and test schedule for vetting by IN/ NEC (Mbi). On approval of the plan and
schedule by IHQ MoD(N), the UPS to be subjected to EMI/EMC testing as per the
requirements and test results/graphs be submitted to IHQ MoD (N) post scrutiny/vetting
of IN/ NEC (Mbi).

2. ESD Protection. The system design will take into account adequate measures
for Electro Static Discharge (ESD) control and protection at PCB/module/assembly and
unit level. Each Electro Static Discharge sensitive part/assembly will be duly marked
with a symbol/warning. The manufacturer will use ESD protective materials for handling,
packaging storage and transport. The immunity to electrostatic discharges shall be
tested according to IEC 61000-4-2.

3. The equipment are to be designed for EMI/EMC compatibility by providing

suitable EM gaskets and Cu-Be strips at openings and are to be properly grounded. AC
lines are to be filtered for RFI in each cabinet. Shielded twisted pair cables are to be
used where signals are susceptible to interferences. Multi-core twisted pair cables with
overall shield are to be used for signal and control data interconnection and they are to
be properly terminated. The DC supplies are to be adequately filtered and each PCB is
to be provided with transient suppressors.

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 Appendix ‘F’
(Refers to Para 12 of Chapter I)

GENERAL STANDARDS AND SPECIFICATIONS

SUPPLIER’S SCOPE OF SYSTEM SUPPLY

1. Power Rating

(a) Equipment shall be provided with adequate markings in order to specify

input supply requirements & output supply ratings.

(b) For equipment with multiple rated voltages, the corresponding rated
currents shall be marked such that the different current ratings are separated by
a solidus (/) and the relation between rated voltage and associated rated current
appears distinctly.

(c) Equipment with a rated voltage range shall be marked with either the
maximum rated current or with the current range.

(d) The markings of input & output shall include in addition to the following:

(i) Output rated voltage.

(ii) Output rated current or rated power in volt-amperes or active power

in watts.

(iii) Output rated power factor, if less than unity, or active power and
apparent power or active power and rated current.

(iv) Number of output phases (1Φ – 3Φ) with or without neutral.

(v) Output rated active power, in watts or kilowatts.

(vi) Output rated apparent power in volt-ampere or kilovolt-ampere.

2. The supplier's scope of system supply shall cover the supply of equipment,
Installation Material, Spares, Drawings and Documentation of UPS. The supplier is to
list down in detail, the deliverables to be provided to the customer at various stages of
supply as mutually agreed upon. The complete scope of supply of the system by
supplier shall include material as given in succeeding paragraphs.

44
3. Installation Material. One set of installation material that includes connectors,
shock mounts, special fasteners, special tools, special fittings etc. which shall be
supplied by the supplier as applicable.

4. Testing and Tuning Spares. The supplier shall recommend one set of
Testing and Tuning Spares as required for installation and maintenance onboard.

5. Special Tools and Test Equipment. The OEM is to provide details of

following test equipment that would be required taking into account IN's maintenance
philosophy.

(a) Onboard Test Equipment. This should be adequate to meet the

requirement of all repairs/ maintenance expected to be carried out onboard ship by
the ships staff.

(b) Special Test Equipment. Special-to-type test equipment, if applicable

shall be made available in the shore base for specific tests/checks on the
equipment.

6. Service of Engineer. The supplier is required to provide the necessary

representative(s) during the following phases to assist in carrying out wherever
necessary:-

(a) Installation of UPS onboard ships.

(b) Onboard Trials.

7. Onboard Spares (OBS). The supplier shall prepare the list of OBS (including
onboard maintenance tools) based on the Reliability and Maintainability data and taking
into account IN’s maintenance philosophy, and shall forward to IHQ MoD (N)/DEE for
vetting during the pre-bid meeting. The manufacturer should clearly indicate the basis
for ranging and scaling of spares. This should include the list of spare parts, tools and
accessories, which must be carried on the ship, for preventive maintenance, trouble
shooting and quick repairs to ensure no more than 30 minutes of ‘Down Time’ for the
system at any given instance. One set of OBS is to be supplied with the system. The
complete inventory of system parts including OBS & B&D spares is to be provided in
INCAT (Indian Naval Catalogue of Inventory) compatible format in electronic media for
ILMS (Integrated Logistics Management system) of Indian Navy, for the management of
spares. The supplier shall provide both hard copy as well as soft copy. PCBs offered as
OBS should also undergo Endurance Test either on a reference system or on main
system. However, in case the quantity of PCBs is large, Endurance Test to be
conducted on a sampling plan, approved by Inspection Authority. List of all spares/items
used in the system with the following classification and details is to be provided to the IN
during the pre-bid meeting:-

45
 (a) COTS / Non-COTS items.
(b) PCB or module functionality - Processor Function/ Input - Output Function
(c) With /without embedded software.
(d) Produced by vendor quoting/ sourced.
(e) Repairable by vendor quoting/ repaired by third party.
(f) Checked by BITE/Not Checked by BITE.
(g) Estimated MTBF in hours.
(h) Circuit diagrams available/not available.
(j) Consumables like fuses, indication lamps etc.
(k) Numbers/quantity fitted the system.
(l) Shelf life of spare.
(m) Itemised cost of all items.

8. Five Year Base and Depot Spares. The OEM should forward recommended
list of B&D spares, tools and test equipment for vetting of IHQ MoD (N). B & D Spares
should consist of spare parts and modules required to replenish depot holdings for a
period of five years. These should also contain complete subsystems and assembly
spares for the major refit (and thorough checking thereafter) of the system. It should
also include exclusive Depot Spares comprising PCBs. The manufacturer should clearly
indicate the basis for ranging and scaling of spares. The supplier shall also provide
finalised / approved list of B&D spares in Indian Naval Catalogue of Inventory (INCAT)
databank compatible format in electronic media. The onboard, base and depot, testing
& tuning spares and long term exploitation spares should be indicated with a standard
part no for identification and traceability as per Navy’s standards. Order for B&D spares
would be placed separately. Following points in respect of spares of the equipment
needs to be mentioned :-

(a) The basis of ranging and scaling to be clearly indicated.

(b) Commitment from the manufacturer for continuous customer and spare
support for a specified duration for the life of the equipment.

(c) Commitment to undertake up gradation of the spares if required due to

non-availability of the spares due to obsolescence.

(d) The supplier is required to indicate the make and part no. of each item.
The details of spares are to be provided in ILMS format (both hard copy and soft
copy to be provided).

(e) Base spares recommendation is to cover maintenance / overhaul

requirements for 5 years including two refits.

(f) The details of tools and STTE required for carrying out 3rd and 4th level
maintenance to be included in the offer.

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 (g) The supplier shall provide average life of all B & D spares and specify the
turnaround time required for repairs/replacement of each spare.

9. Drawings and Documentation. Detailed data and information related to

installation procedure, operation and maintenance manuals, maintenance schedules
and test certificates for major components are required to be furnished as below by the
manufacturer: -

(a) Firm is required to submit one hard copy and one soft copy of the draft
system documents to Navy for vetting at least 3 months prior to conduct of ATP
of the equipment.

(b) One set of finalised/ approved documents should be supplied with the
equipment. Additional 6 sets (hard copy) and one soft copy on CD ROM of
documents should also be supplied.

(c) Supply of documents will be part of the order and should be costed for in
the order.

(d) Documents in CD-ROM are to be as per Level 4 Interactive Electronic

Technical Manual (IETM).

(e) The documentation and drawings as applicable shall contain complete

information for installation, operation, inspection, maintenance, repair / overhaul,
testing and trials and should include the following:-

Ser Description Remarks

(i) Design The design specification for the System and its
Specifications role needs to be mentioned.

(ii) User hand book Covering composition and brief description of

equipment with block diagram; Technical
parameters; Brief technical description with
Photographic or graphical representation of
each unit; Detailed functional and Operating
instructions giving safety instructions,
precautions, Switching-on and switching off
procedures, Tables of fault indication and fault
codes etc; Storage, Preservation / De-
preservation, Transit Procedure etc.

47
 (iii) Technical Covering detailed technical description of each
manual unit with associated drawings and diagrams. It
should also include data on Integrated circuits
and semiconductor components

(iv) Installation Covering composition of equipment,

manual Cabling diagram and cable specifications,
Cable connection schedule, Complete binding
data, Installation drawings, List of installation
materials, List of Accessories, Detailed
installation instructions.

(v) Maintenance Covering Instructions on servicing; Planned

and Preventive Maintenance; on dismantling and
Repair manual assembling of each unit; Faults, their causes
and remedial action; Repair, overhaul
&Reconditioning, Testing, adjusting,
calibrating and tuning of each unit, List of
special tools, test equipment, Jigs and gauge.

(vi) Maintenance Comprehensive Maintenance Schedules

Schedule are to be provided along with system. These
schedules should cover all the relevant
aspects and provide the user/maintainer with
adequate literature for reference, to prepare
the Engg. Support Documents.

(vii) Part catalogue, The manual should include-

List of (a) Catalogue of parts listing out all the
spare parts, replaceable parts
Test (b) List of On board spares
equipment (c) List of B&D spares
(d) List of test equipment
(e) Service Log Books

(viii) Instructions on Containing instructions on Testing and

Testing & Tuning, alignment, Checking and adjustment
Tuning and to individual parts and of the equipment as a
Setting To Work whole.

(ix) System Containing technical details of all the hardware

Integration Plan and software interfaces with the external
systems.

48
 (x) 'As Made' As applicable
drawings

(xi) Test As applicable

data/certificates

(xii) Test and Trial (a) In-production Test Procedures

schedules (b) Engineering, Environmental and
Quality Inspection Procedures
Installation Check Schedule

10. Binding Data. Three hard copies and two sets on CD ROM of the following
binding drawings/ documents are to be supplied by the OEM within 3 weeks of
placement of order: -

(a) Block diagram of the system

(b) Installation documents covering detailed procedure for installation with
sequence of activities.
(c) Installation drawings indicating overall dimensions, C.G., weight,
maintenance envelope etc of each unit.
(d) Recommended arrangement of devices in nominated compartments.
(e) Inter unit-cabling diagram with cables specifications.
(f) Cable connection Schedule.
(g) Power supply scheme for the system.
(h) Heat Dissipation of individual units in compartment & in close loop
ventilation system, as required for the system.
(j) Parts identification list, indicating part no, qty., maker's name,
Specification etc.
(k) Detailed foundation drawing including bolting plan.

11. Shipping. All equipment shall be adequately packed and protected with
supports to ensure adequate protection during all modes of transportation. Each unit
within a package/container shall be clearly marked for identification. The container shall
clearly indicate the item description with caution marks, quantity, weight, size etc. A
separate document giving details and instructions for storage, preservations, handling
and transportation after delivery is to be supplied. The supplier should indicate the
delivery schedule, transport, packing, preservation, insurance etc.

12. Preservation, Packaging and Shipping. The stores (including OBS and B&D
Spares) shall be supplied in long-term preserved condition that is suitable for storage
under tropical high humidity conditions for a period of 24 months.

13. Part Identification List. The OEM shall prepare and submit a Parts Identification
List (PIL) list, showing exploded views of equipment supplied to the Line Replaceable

49
Unit (LRU) level, which shall include exploded view drawings of all equipment clearly
showing how equipment is assembled. All equipment and components shown shall be
identified by OEM part number shown in a tabulated parts list provided with the drawing.
The PIL shall be organised such that it supports logical retrieval of data. The PIL
description shall be part of the Operator's and Maintenance Manual. The PIL shall be
included in the CD-ROM technical manual. (The Parts Identification list that gives the list
of items up to LRU level is to be submitted at the time of submission of offer).

50
 Appendix ‘G’
(Refers to Para 13 of Chapter I)

GENERAL STANDARDS AND SPECIFICATIONS

PRODUCT SUPPORT

IN Maintenance Philosophy

1. Onboard Repair/ Maintenance. Onboard repair shall be restricted to

replacement at PCB/ Modules (LRU) level. Routine maintenance and serviceability
check/terminal performance checks would also be undertaken by ships staff as part of
1st line maintenance.

Product Support from Vendor

2. The supplier should undertake to ensure guarantee and continuous product

support for a period of 15 years from the date of supply of the first system and
associated equipment, by way of the following: -

(a) Supply of spare parts and materials.

(b) Offering of alternative solutions in the event of obsolescence of the
components/technologies, including those bought out or subcontracted.
(c) Continuous up-gradation program.
(d) Modifications and repairs.
(e) Provide at least two years notice, in the event of any likely production
shut down (only after 10 years of support) to enable procurement of LTE
spares.
(f) Undertake repairs through Annual Maintenance Contract/Rate Contracts
as and when directed by the user / IHQ MoD(N).
(g) Continuous supply of amendments to the documentation.

3. Repair Facilities. If required by the order placing authority, a consolidated

test bench to test the modules/PCBs of the equipment would be required to be
provided by the OEM as part of Dockyard Support Package. Beyond first level
maintenance facilities on board, the manufacturer would be required to setup requisite
advance level maintenance facilities at locations (Naval dockyards) specified by IN as
part of the Dockyard Support Package

4. Hardware Warranty. The warranty period of UPS system should be for

duration of 18 months from the date of completion of commission and onboard trials.

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5. Training. The Training program objective is to enable the End User Personnel
to operate, maintain, and install the UPS system. The Training package is to include
the following:-

(a) Basic Training. The manufacturer should undertake the responsibility

of training naval personnel (including civilian personnel of the yard), as
nominated by IHQ MoD (N), on the exploitation and maintenance of the UPS
system. The duration of training and number of personnel should be worked out
by the manufacturer in consultation with IHQ MoD (N)/ OPA.

(b) Advanced Training. If required the manufacturer shall also

undertake the training of naval and defence civilian personnel, in carrying out
major repairs in the Naval dockyard by using Special Test Equipment/ Special
Maintenance Equipment. The training shall include assembling and dissembling
of the equipment up to PCB/ component level.

6. Maintenance. The manufacturer should forward recommended maintenance

schedules for preventive and corrective maintenance of the system within three
months of placement of order for necessary approval at IHQ/OPA.

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 Annexure
(Refers to Para 9 of Appendix ‘D’)

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