CONTENTS

Page No.

TITLE PAGE

TABLE OF CONTENTS

1.0

PURPOSE

2.0

SCOPE

3.0

DEFINITIONS

4.0

REFERENCE STANDARDS AND CODES

5.0

RESPONSIBILITIES

6.0

TEST EQUIPMENT CONTROL

7.0

QUALITY CONTROL

8.0

TESTING PROCEDURE

9.0

DOCUMENTATION

NO : Q2.ESD.09, REV :AA

DATE : JUNE 2012

DISCIPLINE :

ELECTRICAL

TITLE

PROCEDURE FOR SITE ACCEPTANCE TESTING OF

STATION BATTERIES

1.0

PURPOSE
To ensure that the station batteries are installed in accordance with design
specifications, that their characteristics are within applicable standards and
manufacturers tolerances.

2.0

SCOPE
This procedure shall apply during the site acceptance testing of station batteries.

3.0

DEFINITIONS

3.1
3.2
3.3
3.5

C.E.
C.M.
T.T.
Q.C.

4.0

REFERENCE STANDARDS AND CODES

4.1

4.2

TCP-P-105-00 Pre-commissioning Testing Procedure

NEC National Electrical Code

5.0

RESPONSIBILITIES

Commissioning Engineer
Construction Manager
Testing Technician
Quality Control

5.1 The Commissioning Engineer (C.E.) shall be responsible for preparing the testing plan,
for the observance of all safety precautions required by the JAL Safety Plan, for
supervising the testing activities.
5.2 The Testing Technicians (T.T.) shall be responsible for carrying out the tests, recording
the test values.
5.3
The QC Department shall be responsible for conducting reviews of the test records
to ensure that all tests have been performed in accordance with the approved
inspection and test plan.
6.0

Test Equipment Control

3

NO : Q2.ESD.09, REV :AA

DATE : JUNE 2012

The Commissioning Engineer shall carry out an inspection of the test equipment
when the test equipment arrives in the warehouse. Each piece of test equipment
shall have the calibration labels intact. The Commissioning Engineer shall ensure
that the test equipment manual is available and that the test equipment is calibrated
and calibration certificates are available.
The Commissioning Engineer will keep a record with the test equipment serial
numbers, date of calibration and copies of the calibration certificates. JAL will
submit copies of the calibration certificates of the test equipment to Al-Mashariq.
The Commissioning Engineer shall ensure that test equipment that it is out of
calibration is isolated in a quarantine zone and will be sent as soon as possible to a
certified metrology laboratory for re-calibration against national standards.
The Testing Technicians shall ensure that the test equipment is tested for proper
operation before starting any test. Any defective test equipment will be isolated in a
quarantine zone and sent as soon as possible for repairs.
QC Department shall conduct periodic audits on the test equipment to ensure all
test equipment is within the required calibration period.
7.0

Quality Control
The Commissioning Engineer shall prepare the testing plan that will include the
equipment to be tested, the tests to be performed, the test equipment to be used,
the test procedure to be applied and the test records to be used. Based on the
testing plan, in coordination with the Construction Manager a testing schedule will
be developed.
The Commissioning Engineer shall organize, supervise and verify the
implementation of the testing schedule.
Any defects or variances from the approved specifications and standards will be
noted during the testing and shall be informed to the Construction Department by
the Inspection Report.
The Testing Technician shall use the pre-commissioning form as a checklist and to
record the results of the testing. The form shall be the quality record document to
identify that the inspection and testing has taken place.
The following tests will be performed and recorded on the pre-commissioning
form:
1. Visual and mechanical check
2. Contact resistance measurement of intercell connectors
3. Electrolyte level and specific gravity measurement
4. Temperature measurement
5. Cell voltage measurement
4

NO : Q2.ESD.09, REV :AA

DATE : JUNE 2012

6. Capacity load test

The following test equipment will be used to perform the above tests:
1. Microohmmeter DLRO or T&R
2. Digital multimeter
3. Battery load unit, BTS
4. Hydrometer
5. Mercury in glass thermometer
8.0

TESTING PROCEDURE
The following shall be the guidelines for the testing personnel during the inspection
and testing of station batteries.

8.1 Visual And Mechanical Check

Compare nameplate data with drawings and specifications.

Inspect physical and mechanical condition.
Verify that the batteries, the terminals and interconnectors are clean and covered with
protective coating.
Check that the battery is filled with electrolyte to proper level.

8.2 Contact Resistance Measurement of Intercell Connectors

Test equipment: Microohmeter DLRO or T&R

Check that the contact surfaces for the current and

voltage probes are clean and dry.
Torque-check the exposed joints of the intercell
connectors. The torquing values should be as per
manufacturer recommendation. Check that the
instrument probes are clean and dry.
Check that the microohmmeter is switched off during
Fig. 1
making connections. Ground the microohmmeter.
Connect the current and voltage cables, with respect to the polarities, as in fig. 1.
Always connect the voltage cables inside the current cables.
Switch on the microohmmeter.
Increase the current to the desired value.
Read the resistance value.
Compare measured values with manufacturers specifications; compare results
between different connections. Differences greater than 50% between connections
should be investigated.

NO : Q2.ESD.09, REV :AA

DATE : JUNE 2012

After the battery charger has been properly checked as per vendor instructions, charge the
battery as recommended by the battery manufacturer and record the temperature and the
specific gravity of the electrolyte, the voltage of each cell at pre-determined time intervals.
After three or more days but less than seven perform the following tests:
8.3 Electrolyte Level And Specific Gravity
Test equipment: Hydrometer

Measure the electrolyte level of each cell.

Measure and record the specific gravity of the electrolyte of each cell.
Compare measured values with manufacturers specifications.

8.4 Temperature Measurement

Test equipment: Mercury in glass thermometer

Measure and record the electrolyte temperature of every sixth cell.

8.5 Cell Voltage Measurement

Test equipment: Multimeter

Measure and record the battery terminal float voltage.

Compare measured value with manufacturers specifications.

8.6 Capacity Load Test

Test equipment: Battery load bank BTS

Switch off the charger and open the battery disconnect switch to isolate the battery
from charger and load.
Disconnect the battery from the charger and the load.
Verify that the battery load bank is switched off.
Connect the battery load bank to the battery as in fig. 2. If is possible the battery load
bank should be installed outside the battery room

NO : Q2.ESD.09, REV :AA

DATE : JUNE 2012

Fig. 2

Set the desired discharge current, alarm level and final voltage level as per
recommendation of the vendor.
Start the test. Measure and record the cell voltage and battery voltage at 10min,
30min., 1hr., 2hr., 4hr., and 8hrs.
Compare the results with manufacturers specifications.

9.0

DOCUMENTATION

9.1
9.2

Station battery instruction manual-vendor documentation

Test equipment operation manuals

NO : Q2.ESD.09, REV :AA

DATE : JUNE 2012