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PROCEDURE P1-GIPL-004
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
1. Purpose
This document gives instruction for carrying out Periodic Maintenance on Valve Regulated Lead Acid (VRLA) Batteries.
2. Scope
This procedure will outline the maintenance routines and responsibilities for all VRLA batteries. This procedure provides general guidelines as applicable to VRLA batteries. The users of this procedure are advised to refer the corresponding OEM (O&M) manual for carrying out all O&M activities.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
Format No.
OEM/0004 OEM/0006 OEM/0013
Frequency
Quarterly Yearly Fortnightly
Location
BTS BTS BTS
Period to be Maintained
1 Year 3 Year 6 Months
Contact the vendor for any manufacturing defects or discrepancies found during the maintenance.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
Inform and take permit from concerned authorities for the work. In case of BTS/FSR/OR/MWR sites, only inform the concerned authorities and no work permit is required. Use a suitable lifting device in handling the battery to prevent damage.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
Verify that the battery area safety equipment is available and operational. This includes the eye wash device in first aid box and fire extinguisher, as applicable. Verify that personal safety equipment is available and in good condition. This includes goggles, face shields, plastic or rubber aprons, and gloves. Verify that battery cleaning and acid neutralization supplies are available. Baking soda, water, a nonconductive container for mixing, and wiping cloths are recommended. Visually inspect the battery area for cleanliness. Assure that the area is dry and clear of debris.
CAUTION: Use only clean water for cleaning battery component. Solvents and greases can damage cell containers. Follow the manufacturers instruction closely to avoid damage to battery.
Visually inspect all cell jars or battery modules, and the battery rack for cleanliness and any signs of distortion or damage. Measure and record the battery area ambient temperature. The desired temperature should be in the range of 21C (70F) to 27C (80F). NOTES: If the battery is located in an enclosure, the ambient temperature should be measured inside the enclosure, not in the surrounding area. Extended operation at a high temperature shortens battery life. In general, VRLA battery life is reduced by at least 50% for every 8.3C (15F) of continuous
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
operation above 25C (77F). At very high temperatures, VRLA batteries are also more susceptible to other failure modes such as dry out or thermal runaway. If a battery is normally maintained at a temperature significantly different than 25C (77F), verify that the float voltage is set in accordance with the manufacturers recommendations. The float voltage shall be reduced by 3 mV per degree centigrade rise of temperature above 27 oC. This is as per recommendations of HBL Nife mentioned in the O&M manual. Verify that the cells have protective covers in place to minimize short circuit safety hazards. Verify that the voltmeter calibration has not expired. Use a calibrated voltmeter with an accuracy of at least 0.5% of the measured voltage. Assure that the voltmeter test leads are well insulated and securely attached to the meter to prevent their falling onto a cell and causing a short circuit. Inspect the entire rack for any loose connections or broken parts. Visually inspect for missing or broken seismic rack parts / spacers. Check that the jar and post seals are not broken. Consult with the manufacturer if post seal failure is suspected. Check the jars / cover for excessive distortion. Check the vent cap tightness by hand. Check for any signs of vibration. Visually check for cracks or signs of electrolyte leakage in each cell. Check for signs of electrolyte leakage from the pressure relief valve and battery terminal poles of each cell. Inspect the flooring below the cells for symptoms of past leakage. If electrolyte leakage is observed, contact the manufacturer to determine if the cells require replacement. Electrolyte leakage can cause a loss of capacity and can lead to other VRLA failure modes. Visually inspect the cell posts for corrosion and damage. Corrosion on the cell posts can indicate a loss of post seal integrity, which can result in rapid dry out and failure of a VRLA battery. Wipe off any signs of corrosion from
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
the posts. Re-grease the post with anticorrosion petroleum jelly if necessary. CAUTION: Because float voltages are accurate cell indicators only when taken on a fully charged battery, be sure that at least 72 hours have elapsed since the system was discharged or equalized. Record the charger output voltage and current. Verify that the output voltage is within the desired range. This shall be 54.5 V + 0.2 V DC for 48 V system including cable drop. CAUTION: Observe the proper polarity when taking voltage measurements to avoid positive and negative calibration differences in the voltmeter. Measure and record the voltage at the battery terminals. Divide this measurement by the number of cells in the battery to confirm that the average individual cell voltage is within the range recommended by the manufacturer. Float voltage for: 2V battery cell = 2.25 V + 0.03 V DC at 27 C. 12V battery cell = 13.5V + 0.03V DC at 27 C If float voltage is outside the recommended range, adjust the charger output to the recommended value in accordance with facility procedures.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
The following checks are specified on a quarterly basis: Fortnightly, inspection as described in Section 4.4, except the float voltage checks are performed on all cells. Short term discharge test or Continuity Test to examine individual cell conditions when individual cell readings are beyond limits.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
Measure the battery ICC joints temperature and the bus bar joint temperature. If the temperature is above 50 0C or the temperatures are unequal then terminate the battery discharge test. Check the bus-bar joints for loose connections. Tighten the connections and continue the battery discharge test.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
The batteries have to be continuously monitored for rise in temp. & for weak cell. Since the batteries are discharged for nearly 20% capacity it must be ensured that the batteries are fully charged after the test. The SMPS should change over to automatic boost mode and should stay in boost for 16 hours. It is advised to start the DG set and charge the batteries.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
Measure the individual cell voltages and record the same on the format as shown in Format No.: OEM/0007. Refer the battery table of HBL Nife mentioned in Format No.: OEM/008 and decide the time duration corresponding to the site load current. Enter parameters like battery test duration, Guard time, Discharge Ah capacity and test end voltage in SMPS parameter, whichever is applicable. Select Start battery discharge test form SMPS. The SMPS shall lower the output voltage of rectifier to the battery test voltage. This allows the battery bank to discharge through the connected load. Note down the individual cell voltages, entire bank voltage, battery ICC joints temperature and the bus-bar joint temperature at an interval of 15 minutes. Terminate the test when the battery terminal voltage decreases to the calculated end voltage (44.4 V DC) or if any individual cell reaches a voltage of 1.85 V for 2V battery. Record the time taken to reach this voltage. Recharge the battery in accordance with the manufacturers instructions and restore it to normal standby service. Check the time of back up as against the design from the table in Format No.: OEM/008. Replacement of battery bank is warranted if the time is less than 70% of the design time. Mark the cells that have reached the voltage of 1.80 before the duration. These cells need separate equalisation or replacement. Subsequent discharge test of the site can be taken up after equalisation or after replacement to ensure the backup time. If at all it is decided to continue the test then the weak cell will have to be removed from the bank and the test to be done with external load. Terminate the test also when the battery ICC joints temperature or the bus bar joint temperature is above 50 C or the temperatures are unequal. Check the bus-bar joints for loose connections. Tighten the connections and continue the battery discharge test.
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
The above step can be carried out only after the SMPS has been switched ON and the DG back up is continuously available.
5.4.7.4 Annual Discharge test using external load (as & when applicable)
Note: In this process there will be no battery backup for the site and hence it is strictly recommended that the DG set is started and the SMPS is switched over to the DG set power supply. In case of sites without DG sets, then DG set need not be hired. Adequate precautions should be taken to conduct the discharge test. Ensure that all safety precautions are strictly followed. Note down the site load current and the battery float voltage. Inform OMC desk about the test and the duration. Start the DG set and ensure that the SMPS is performing satisfactorily on DG set. . If DG set is not available, take adequate precautions. Measure the individual cell voltages and record the same on the format of Format No.: OEM/0007. Disconnect the battery bank by removing the negative fuse using the fuse puller. A DC breaker of at least 1.25 times of the discharge rate has to be installed for switching and clearing any major faults. Connect the external load bank to the batteries. Be careful while connecting the batteries as it has stored energy and can result in short circuits. Close the DC circuit breaker and start the test. Start the timer and begin the load test at the temperature-corrected test discharge rate. Monitor the test current throughout the test and adjust the load bank as needed to maintain a constant test current. Measure and record individual cell voltages, battery terminal voltage, battery ICC joints temperature and the bus-bar joint temperature. Take the readings just prior to starting the test, at the beginning of the test when
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
load is first applied, at periodic intervals of 15 minutes during the test, and at the completion of the test. Maintain the test discharge rate until the battery terminal voltage decreases to the specified average end of discharge voltage per cell times the number of cells in the battery (For 2V battery, 1.75 V x 24 = 42.40 V). Do not continue the test below the specified voltage. Observe the battery during the test for intercell connector heating. Terminate the test when the battery terminal voltage decreases to the calculated end voltage (42.40 VDC) or of any individual cell reaches a voltage of (1.75V for 2V battery). The test can be continued after jumpering the weak cell or by removing the cell from the bank. However it must be noted that the battery bank voltage has now to be recalculated as no. of cells in the bank multiplied by the cutoff cell voltage i.e. 1.75V for 2V battery Terminate the test also when the battery ICC joints temperature or the bus bar joint temperature is above 50 0C or the temperatures are unequal. Check the bus-bar joints for loose connections. Tighten the connections and continue the battery discharge test. Record the total test time. Disconnect the test equipment. Recharge the battery in accordance with the manufacturers instructions and restore it to normal standby service. Check the time of back up as against the design from the table in Format No.: OEM/008 Replacement of battery bank is warranted if the time is less than 70% of the design time.
The above procedure is a general guideline for the discharge test. In case of any doubts regarding this procedure please consult the Core group or the Battery manufacturer for clarifications.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
The following corrective actions need to be taken after evaluating the discharge test: If the discharge duration is less than the set time then consult the manufacturer. Based on the manufacturers recommendation conduct an equalisation charge and redo the above discharge test. Even after the equalisation charge if the battery bank does not provide the design back-up then replace the entire battery bank.
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
4. Individual cells might require replacement when a capacity test or continuity test determines that they are degraded. Unless the battery is nearing the end of its service life or many cells in the battery are degraded, it is acceptable to replace individual cells within the battery. Based on industry experience to date, it is likely that some cells will require replacement in the first 4 years of service.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
inspected and upgraded during the battery replacement, it might be many years before it is looked at closely again. The float voltage of VRLA should be 2.25 V +/- 0.03 V DC per cell for 2V battery and 13.5 V DC + 0.03 V DC per cell for 12V battery at the battery terminals. The SMPS output shall be suitably adjusted to incorporate the voltage drop in the battery cable. For example, if the voltage drop is 0.4V then the rectifier output shall be 54.5V (i.e. 2.25 x 24 + 0.5V or 13.5*4 + 0.5V). The SMPS used for the charging of the battery has boost charging facility. This facility shall be enabled. The boost charge is started automatically once the batteries have discharged more than a set value. This value is generally kept as 6 to 10 %. 5. The preferred charging current for VRLA batteries is 0.1C i.e. 10 % of the battery AH. However for sites with frequent power failures and voltage fluctuations this can be increased up to 0.15 C.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
A capacity test is recommended as part of the installation if the manufacturer did not perform an acceptance test before shipment. The purpose of this capacity test is to confirm adequate battery capacity and to identify any failed cells. If a capacity test is not performed, evaluate the internal ohmic measurements to ensure that all cells are consistent. Abnormal internal ohmic measurements might still require a capacity test to ensure that the battery is acceptable.
PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
voltage will be 54.5 V. These limits are generally applicable for float applications. Sites facing frequent power failures and power fluctuations may adopt slightly higher set voltages. The float voltage can be increased up to 2.27 V per cell for 2V battery; 13.62 V per cell for 12V battery and the boost voltage can be set at 2.37 V per cell for 2V battery; 14.2 V per cell for 12V battery. For a 48 V system the set points shall be 54.9 V for float and 57.3 V for boost charging. The voltages mentioned above shall be read at the SMPS display.
Float Voltage
54.5 V
Boost Voltage
56.5-57.0 V
Values
All Locations- 42.5 V All Locations- 6 to 10% All Locations- 6%
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE P1-GIPL-004
Frequency
Quarterly As and when required Annually As and when required For Information
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