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SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE FOR VRLA BATTERY MAINTENANCE PROCEDURE NO.: P1-GIPL-004
SECTION GIPL-OEM Project and Operation & Maintenance
This document gives instruction for carrying out Periodic Maintenance on Valve Regulated Lead Acid (VRLA) Batteries.
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.
3. Responsibilities 3.1 National Head
Based at Corporate office –Bangalore is responsible for the technical integrity of this procedure. The National Head or his nominated Deputy shall be authorised for any changes with this procedure.
3.2 Circle Manager
The Circle Manager or In-charge is responsible for ensuring that all activities related to this procedure are complied with and recorded as described in this document.
4 Maintenance Process Maintenance Frequency and Records
3 . • Isolate the battery from charger while removing / installing batteries or while tightening the inter-cell connections. • Do not allow metal objects to rest on the battery or fall across the terminals. Check the vent cap tightness by hand. 4. • Do not expose the battery to an open flame or sparks in the immediate vicinity. • Do not tamper with the cell vent since this may cause leakage of the internal gas pressure. 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. • Do not attempt to move the installed battery without removing the connectors. wash the affected area with a continuous flow of water for 15 min. • All tools used for installation should be insulated to avoid accidental shorting of connections.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 Format No. and consult a doctor immediately. • A non-CO2 Class C fire extinguisher must be at work site for emergency.2 Safety Precautions The following safety precautions need to be followed for carrying out any work on the battery system: • Do not touch un-insulated battery connectors or terminals. • Keep the battery clean and dry.. • In case of accidental contact with acid.
only inform the concerned authorities and no work permit is required. cracked container.C. 4.3 Tools Required Calibrated Digital Multimeter Insulated Spanners Torque Wrench (Insulated) Cloth. The following types of problems can be detected during the fortnightly inspection: • Loose connections of the battery • Electrolyte leakage from pressure relief valve.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 • Inform and take permit from concerned authorities for the work. or post seal. In case of BTS/FSR/OR/MWR sites. Clamp Meter for current reading • Protective Clothing • First aid kit • • • • • • • • 5. • Use a suitable lifting device in handling the battery to prevent damage.1 Purpose of Inspection The purpose of the fortnightly inspection is to visually check the general conditions of the battery & battery area including condition-monitoring check of its various parameters. Cotton rags Nylon Brush Eye goggles for VRLA and face shield for flooded cells. Rubber Gloves Infra Red Temperature Scanner (optional) or normal temperature indicator(shall be organised if required) • D. • Improper float voltage • Abnormal battery area ambient temperature (high temperature can reduce battery life and contribute to dry out) 4 .
• Visually inspect the battery area for cleanliness. • Verify that battery cleaning and acid neutralization supplies are available. Baking soda. VRLA battery life is reduced by at least 50% for every 8.2 Inspection Procedure NOTE: Whenever performing maintenance inspections. plastic or rubber aprons. • Measure and record the battery area ambient temperature. CAUTION: Use only clean water for cleaning battery component. Follow the manufacturer’s instruction closely to avoid damage to battery. • Verify that the battery area safety equipment is available and operational. • Verify that personal safety equipment is available and in good condition. not in the surrounding area. Extended operation at a high temperature shortens battery life. Solvents and greases can damage cell containers. a nonconductive container for mixing. and gloves.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 • Improper operation of the battery area ventilation system 5.3°C (15°F) of continuous 5 . as applicable. face shields. The desired temperature should be in the range of 21°C (70°F) to 27°C (80°F). Assure that the area is dry and clear of debris. and wiping cloths are recommended. This includes the eye wash device in first aid box and fire extinguisher. • Visually inspect all cell jars or battery modules. water. ensure that the manufacturer's instruction manuals for the battery and charger are available for review. In general. and the battery rack for cleanliness and any signs of distortion or damage. the ambient temperature should be measured inside the enclosure. NOTES: If the battery is located in an enclosure. This includes goggles.
At very high temperatures. which can result in rapid dry out and failure of a VRLA battery. • Check that the jar and post seals are not broken. 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 25°C (77°F). Check for signs of electrolyte leakage from the pressure relief valve and battery terminal poles of each cell. Consult with the manufacturer if post seal failure is suspected. • Visually check for cracks or signs of electrolyte leakage in each cell. Wipe off any signs of corrosion from 6 . • Check the vent cap tightness by hand. • Verify that the voltmeter calibration has not expired. Electrolyte leakage can cause a loss of capacity and can lead to other VRLA failure modes. If electrolyte leakage is observed. • Visually inspect for missing or broken seismic rack parts / spacers. verify that the float voltage is set in accordance with the manufacturer’s recommendations. Use a calibrated voltmeter with an accuracy of at least 0. The float voltage shall be reduced by 3 mV per degree centigrade rise of temperature above 27 oC. Inspect the flooring below the cells for symptoms of past leakage.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 operation above 25°C (77°F). • Visually inspect the cell posts for corrosion and damage. • Check for any signs of vibration. Corrosion on the cell posts can indicate a loss of post seal integrity. • Inspect the entire rack for any loose connections or broken parts. This is as per recommendations of HBL Nife mentioned in the O&M manual. contact the manufacturer to determine if the cells require replacement. • 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.5% of the measured voltage. • Check the jars / cover for excessive distortion. • Verify that the cells have protective covers in place to minimize short circuit safety hazards.
25 V + 0. be sure that at least 72 hours have elapsed since the system was discharged or equalized. • Measure and record the voltage at the battery terminals.6 Quarterly Inspection 4. the quarterly inspection for a VRLA battery is intended to confirm that excessive internal battery degradation has not occurred. Verify that the output voltage is within the desired range. 7 . 12V battery cell = 13.5V + 0. CAUTION: Because float voltages are accurate cell indicators only when taken on a fully charged battery.03V DC at 27 °C • If float voltage is outside the recommended range. CAUTION: Observe the proper polarity when taking voltage measurements to avoid positive and negative calibration differences in the voltmeter. This shall be 54. Also.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 the posts. adjust the charger output to the recommended value in accordance with facility procedures.1 Purpose of Inspection The quarterly inspection provides confirmation that the battery and individual cells are being maintained within recommended operating limits.2 V DC for 48 V system including cable drop.03 V DC at 27 °C. Re-grease the post with anticorrosion petroleum jelly if necessary.6. • Record the charger output voltage and current. 4.5 V + 0. 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.
8 . • When the voltages of individual cells are lower than normal. • Measure and record each cell float voltage. Record the results in the format as shown in Format No. Ensure that the voltage readings are within the tolerance specified by the manufacturer for the particular battery.4 • Inspect all cables connected to the battery.6.4. it is possible to conclude that insufficient charging has occurred. • Perform the fortnightly inspection as specified in 4.30V DC then proceed with the continuity test as per the following procedure 3.03 V DC for 2V battery cells and 13. • If the individual cell voltages are beyond the range mentioned above i.03 V DC for 12V battery cell at 27 0C.5. • Check the vent cap tightness by hand.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 The following checks are specified on a quarterly basis: • Fortnightly.20V DC and more than 2.5 V DC + 0.: OEM/0004 for quarterly maintenance of VRLA battery.6. • Short term discharge test or Continuity Test to examine individual cell conditions when individual cell readings are beyond limits.2 Inspection Procedure Refer Format No.2. less than 2. except the float voltage checks are performed on all cells. Do not apply more than 10 Nm torque.25 V DC + 0. If any individual cell measurement exceeds the manufacturer’s recommended tolerance.4. Check for any overheating/looseness. individual cell voltages should be within + 0. 4. This is generally between 2.e. Compare the cell voltages to the range recommended by the manufacturer. • With proper float operation at recommended voltages. • Tighten all inter-cell connections using a torque wrench.03 volts of the average cell voltage.3 to find out weak cells in the bank.: OEM/0007. inspection as described in Section 4. investigate for abnormal conditions.
If DG set is not available.6. This allows the battery bank to discharge through the connected load. If the temperature is above 50 0C or the temperatures are unequal then terminate the battery discharge test. shall be done using the SMPS parameters. • Determine the durations of the test based on the battery AH capacity and the load current. wherever possible. The following precautions need to be followed before this test: • Ensure that the DG set is available and healthy by taking a trial run. Refer the following section for deciding the duration of the test. • Enter parameters like battery test duration. • Select Start battery discharge test form SMPS. 9 . 4. Battery discharge test using SMPS parameters: Short term discharge test and annual discharge test methods are explained in the subsequent paragraphs. • The SMPS shall lower the output voltage of rectifier to the battery test voltage.3 Short Term Discharge test or Continuity test Follow the steps given in the Guidelines for battery discharge test through SMPS. Refer Format No.: OEM/0005 for short discharge test activities. The discharge tests. • Inform OMCR Shift Head before conducting the test. Discharge Ah capacity and test end voltage in SMPS parameter. Guard time.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. take adequate precautions. Tighten the connections and continue the battery discharge test. Enter the value in SMPS parameter. Check the bus-bar joints for loose connections. whichever is applicable (One time activity).
: OEM/0007.6. Check the bus-bar joints for loose connections.6 V DC. In a similar fashion we can calculate the duration for other rating battery banks.85V DC for 2V battery. The battery should have greater than 80% of its original capacity when the test is complete. We can deduce from the table that for a load of 55A the total discharge time available is 5 hours.3. For example a site with 320AH batteries and a load of 55A the test duration can be calculated as follows: Duration in minutes = AH capacity x 60 min x 0. determine the minimum allowed DC voltage and establish test termination criteria above this minimum voltage. it is not intended that a continuity test fully discharge the battery. Tighten the connections and continue the battery discharge test.90 V DC.1 Determining the duration of the Short term Discharge test Refer Format No. “0. To initiate 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. Based on the total load and the battery’s rated capability. The SMPS should change over to automatic boost mode and should stay in boost for 16 hours.2 / 55A The duration works out to approximately 70 minutes. The individual cell voltages and entire bank voltage shall be recorded at every 15 minutes interval on the format mentioned in Format No. refer the guidelines for battery discharge test through SMPS. 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. 10 . or if any of the individual cell voltage falls below 1. • Since the batteries are discharged for nearly 20% capacity it must be ensured that the batteries are fully charged after the test. Also.: OEM/0005 for the discharge duration of HBL Nife batteries for an end cell voltage of 1. The test shall be terminated if the bank voltage falls below the limit of 45. determine how long to conduct the continuity test. 4. It is advised to start the DG set and charge the batteries. & for weak cell.2” in the above formula represents the AH capacity to be discharged.
Similarly there are two battery banks in IS and hence we do not need a PE. Hence it is ideal to carry out the discharge test using external load for individual banks.7. However the batteries of MCN have to be discharged under a PE window.4. It is designed to allow trending of the battery’s capacity by discharging the battery at a constant current or power to a predefined endpoint voltage and comparing the actual discharge time to the manufacturer’s rated discharge time. Follow the steps given in the Guidelines for battery discharge test through SMPS.3. Also the battery backup of the IS station is more than 4 to 5 hours. • Measure and record the float voltage of each cell just prior to the test. 5. If cell is not picking up after equalising charge also then arrange for replacement. • Measure and record the cell temperature of 10% or more of the cells just prior to the test to establish an average temperature. If the SEB supply is unreliable then it is recommended to carry out the charging using the site DG set.4.6.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 4. 11 . • If the entire battery bank voltage falls below 45. The annual discharge test for batteries of BTS does not need a planned event (PE).90 V and equalize charge the battery for revival of battery cell. 5.7 Annual Discharge (Capacity) Test A capacity discharge test determines the extent to which a battery is capable of supplying the manufacturer’s rated discharge current for a given duration under a specific set of conditions.6 V DC within the set duration then consult manufacturer for an equalisation of the bank and a Capacity Discharge test.2 Corrective Actions The following corrective actions need to be taken after the test and evaluation of results: • Mark the individual cells that have reached a voltage of 1.1 Initial Conditions before the test • Ensure that the battery bank is fully charged for at least 48 hours prior to the test. As per IEEE 1188 this test should be conducted once a year.
4.2 Precautions before the test • Ensure that the DG set available at site is healthy by conducting a manual trial. • The batteries have to be continuously monitored to ensure that a loss of power does not occur. • Inform NOC/OMC desk before conducting the test.: OEM/0006 for carrying out annual discharge test of VRLA battery.4 Annual Discharge test using site load • Ensure that all safety precautions are strictly followed. • Since the batteries are discharged for nearly 90% capacity it must be ensured that the batteries are fully charged after the test.4. If necessary the DG set can be put into service for charging of batteries.3 Methodology for the discharge test Refer Format No.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 • Measure and record the battery terminal float voltage. Refer the following section for deciding the duration of the test. The rating of the load bank must be at least 20% of the battery AH capacity. For example for a battery bank of 320AH. If the site load is more than the 3-hours discharge rate of the battery bank then the test has to be done using the site load and no external load is required. 5. 5.7.7. 12 . 5. • Note down the site load current and the battery float voltage. However if the site load is less than 3-hours discharge rate then it is recommended to use an external load bank of suitable rating. The following sections elaborate the procedure for both these methods. If DG set is not available. • Determine the durations of the test based on the battery AH capacity and the load current. the load bank must be suitable for a continuous rating of 64A.4.7. take adequate precautions. The discharge test can be carried out either with the site load or by using an external resistive load bank. This decision will be based on the site load.
Tighten the connections and continue the battery discharge test. • Select Start battery discharge test form SMPS. • Mark the cells that have reached the voltage of 1. • Check the time of back up as against the design from the table in Format No.: OEM/0007. Replacement of battery bank is warranted if the time is less than 70% of the design time. • Refer the battery table of HBL Nife mentioned in Format No. These cells need separate equalisation or replacement. • Note down the individual cell voltages. entire bank voltage. Guard time. • Subsequent discharge test of the site can be taken up after equalisation or after replacement to ensure the backup time. whichever is applicable.: OEM/008 and decide the time duration corresponding to the site load current. Discharge Ah capacity and test end voltage in SMPS parameter.4 V DC) or if any individual cell reaches a voltage of 1. 13 . This allows the battery bank to discharge through the connected load.80 before the duration. • 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. • The SMPS shall lower the output voltage of rectifier to the battery test voltage. • Terminate the test when the battery terminal voltage decreases to the calculated end voltage (44. Record the time taken to reach this voltage. Check the bus-bar joints for loose connections. • 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.85 V for 2V battery. • Enter parameters like battery test duration.: OEM/008.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. • Recharge the battery in accordance with the manufacturer’s instructions and restore it to normal standby service. battery ICC joints temperature and the bus-bar joint temperature at an interval of 15 minutes.
battery ICC joints temperature and the bus-bar joint temperature. at the beginning of the test when 14 • • • • . If DG set is not available.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. Measure the individual cell voltages and record the same on the format of Format No.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. Start the DG set and ensure that the SMPS is performing satisfactorily on DG set. • • • • • • • • Ensure that all safety precautions are strictly followed. Adequate precautions should be taken to conduct the discharge test. Inform OMC desk about the test and the duration. take adequate precautions. 5. Note down the site load current and the battery float voltage.: OEM/0007.4. Measure and record individual cell voltages. Close the DC circuit breaker and start the test. . Start the timer and begin the load test at the temperature-corrected test discharge rate. Take the readings just prior to starting the test. A DC breaker of at least 1. battery terminal voltage. In case of sites without DG sets.25 times of the discharge rate has to be installed for switching and clearing any major faults. Disconnect the battery bank by removing the negative fuse using the fuse puller.7. Connect the external load bank to the batteries. Monitor the test current throughout the test and adjust the load bank as needed to maintain a constant test current. then DG set need not be hired. Be careful while connecting the batteries as it has stored energy and can result in short circuits.
Terminate the test when the battery terminal voltage decreases to the calculated end voltage (42. of cells in the bank multiplied by the cutoff cell voltage i. and at the completion of the test.e. 1. at periodic intervals of 15 minutes during the test.4. The above procedure is a general guideline for the discharge test. Recharge the battery in accordance with the manufacturer’s instructions and restore it to normal standby service.40 V). Do not continue the test below the specified voltage. Check the time of back up as against the design from the table in Format No. In case of any doubts regarding this procedure please consult the Core group or the Battery manufacturer for clarifications. The test can be continued after jumpering the weak cell or by removing the cell from the bank.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. Disconnect the test equipment. 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. However it must be noted that the battery bank voltage has now to be recalculated as no.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 • • • • • • • • • load is first applied.40 VDC) or of any individual cell reaches a voltage of (1.5 Corrective Actions 15 . Observe the battery during the test for intercell connector heating. 5.: OEM/008 Replacement of battery bank is warranted if the time is less than 70% of the design time.75V for 2V battery).75 V x 24 = 42.7. Tighten the connections and continue the battery discharge test. Record the total test time.
at. trending of battery performance should allow maintenance personnel to predict when replacement will be necessary. 16 . 5. the installed battery eventually requires replacement. 2.5 Replacement Criteria 1. Any of the following conditions can require a battery replacement: • Capacity below. the impending need for replacement should be identified and budgeted. Over the life of any backup power system. Larger battery installations should be planned as far in advance as possible. Smaller batteries might not need as much leadtime for evaluation.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. When the predicted end of life for a battery is less than 2 years away. Except for cases of sudden battery degradation. or approaching 70% (as determined by a capacity test) • Age approaching the manufacturer’s predicted service life • Continuity test indicating low battery capacity • Excessive number of individual cell failures such that the entire battery should be replaced rather than individual cells • Load growth that prevents the battery from meeting its load requirements • New or revised design requirements • Severe battery degradation 3. • Based on the manufacturer’s 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.
The other equipment also ages. Replace as necessary. • As part of the battery replacement. it is acceptable to replace individual cells within the battery.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 4. Inspect contacts on relays for signs of pitting or burning. it is likely that some cells will require replacement in the first 4 years of service. make everything in the system as new as possible. Check the voltmeter calibration at the float and equalize voltages. • Inspect the battery rack for damage or corrosion. The rest of the system should be inspected and upgraded. Evaluate the output filter capacitors and replace if necessary. as part of the battery replacement. While the battery is out of service for replacement. Based on industry experience to date.6 Check of Other Equipment • For a good battery installation. Individual cells might require replacement when a capacity test or continuity test determines that they are degraded. The charger should receive special attention as part of a battery replacement. Check the setting of other voltage relays. Check the charger failure alarm by opening the AC breaker. • Complete the following: If the new battery has a larger capacity. • Inspect cabling for aging or damage. perform the following: • Inspect DC system breakers. not just the battery. 5. Replace as necessary. • Replace older fuses in the DC system as a precautionary measure. confirm that the charger size is still adequate. as needed. If it is not 17 . a battery replacement is a relatively rare event. Check for loose connections and evidence of overheating. Unless the battery is nearing the end of its service life or many cells in the battery are degraded.
For example. 10 % of the battery AH.5V or 13.25 V +/.4V then the rectifier output shall be 54. The preferred charging current for VRLA batteries is 0. it might be many years before it is looked at closely again. Verify that the cells were stored in accordance with the manufacturer’s recommendations.0. . • The SMPS used for the charging of the battery has boost charging facility. The installed location and configuration must comply with the manufacturer’s requirements. 2. Once the battery is installed.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 inspected and upgraded during the battery replacement.e. Torque all intercell connections in accordance with the manufacturer’s specifications.25 x 24 + 0. • 5.03 V DC per cell for 2V battery and 13. These resistance measurements will form the basis for future acceptance criteria. Perform the following maintenance-related tasks as part of the installation: Inspect all cells for damage before installation.5V). if the voltage drop is 0. This facility shall be enabled.5V (i.7 Maintenance Checks of a New Battery 1. 2.e. If a micro-ohmmeter is available.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.5 V DC + 0. However for sites with frequent power failures and voltage fluctuations this can be increased up to 0.5*4 + 0. This value is generally kept as 6 to 10 %.15 C. 18 .1C i. apply an initial charge in accordance with the manufacturer’s recommendations. • The float voltage of VRLA should be 2. take a baseline set of intercell and termination resistance measurements. Review all manufacturers’ recommendations for the installation and operation of the battery. The boost charge is started automatically once the batteries have discharged more than a set value.
8 Equalisation Charging of VRLA batteries The equalisation charging of the batteries needs to be done whenever the battery cell voltages are not equal (differ by more than + 0.e. This charging needs to be done in consultation with the battery manufacturer.1 V then contact the manufacturer. If a capacity test is not performed.75 V for 2V battery. as the battery bank may need replacement. • Check the individual cell voltages after the charging. Precaution has to be exercised while doing the discharge with site loads. 1. The readings shall be recorded in the format used for annual discharge test. The purpose of this capacity test is to confirm adequate battery capacity and to identify any failed cells. 5. evaluate the internal ohmic measurements to ensure that all cells are consistent. Continuous monitoring of the individual cell voltage and the bank voltage has to be ensured. Charging must be carried out at a rate not exceeding 0.9 Charging current limits The battery bank of VRLA cells must be charged using constant voltage chargers.5 Volts and for float charging 19 .03V). All the cells have to be discharged. For a 48V battery bank the boost charging voltage will be 56. This can be found out from Short term discharge test or from annual discharge test.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. 5. Abnormal internal ohmic measurements might still require a capacity test to ensure that the battery is acceptable. The following precautions need to be taken before the equalisation charge: • The battery bank has to be completely discharged up to end cell voltage i. • Charge the battery bank with 0.20 C10 amperes.2 C rate current for a period of at least 21 hours. If the variation is more than 0.1 C to 0.
PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 voltage will be 54.5 V Boost Voltage 56.5 V.37 V per cell for 2V battery. 13. Permissible limits at SMPS (Considering 0.5 V All Locations.4 – 0.5V cable drop): Site All Locations Float Voltage 54. For a 48 V system the set points shall be 54.3 V for boost charging.6% 20 .27 V per cell for 2V battery. These limits are generally applicable for float applications.9 V for float and 57.6 to 10% All Locations.2 V per cell for 12V battery.0 V Critical Battery parameters: Parameters BLVD BPCL Boost Charging Enabling AH Values All Locations.5-57.62 V per cell for 12V battery and the boost voltage can be set at 2. Sites facing frequent power failures and power fluctuations may adopt slightly higher set voltages. The voltages mentioned above shall be read at the SMPS display. 14. The float voltage can be increased up to 2.42.
Description OEM/0004 OEM/0005 OEM/0006 OEM/0007 OEM/0008 ESCS for Quarterly Maintenance of VRLA Battery ESS for VRLA Battery Short Term Discharge Test ESS for VRLA Battery Annual Discharge Test Format to record Individual Cell Voltages of VRLA Battery during Discharge test Table for Evaluating HBL Nife Battery Discharge Duration ( only reference ) Frequency Quarterly As and when required Annually As and when required For Information 21 .PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-004 5.10 Formats. Records & Frequency Format No.
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