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SHUWEIHAT O&M LIMITED PARTNERSHIP

Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003

Care and Maintenance of Batteries

Prepared Status Approved Name: G.Chaturvedi

Reviewed Frank Siegmund Ian Coupland

Approved Sd/ -

Date: 22 November 2003 29 November 2003

17 December 2003 Page 1 of 16

Technical LP 015

SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 AMENDMENT RECORD Revision Description Date Approved Technical LP 015 Page 2 of 16 .

2.2.0 4.2 5.0 5.4 5.3 5.0 2.2.2.1 5.0 5.2.2.1 5.5 5.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 OVERALL TABLE OF CONTENTS Amendment Record Overall Table of Contents Abbreviations List Glossary of Terms Signs And Symbols 1.6 5.2 5.0 3.3 Policy Purpose Scope Responsibilities Procedure Safety Lead Acid Batteries Voltage Readings Specific Gravity Readings Temperature Readings Contact Resistance Readings Visual Inspections Capacity Test to Determine Replacement Nickel Cadmium Batteries 2 3 5 6 7 8 8 8 8 8 8 9 9 10 10 11 11 11 11 Page 3 of 16 Technical LP 015 .

4 5.4 General Voltage Reading Temperature Readings Visual Inspections Contact Resistance Readings Battery Discharge Testing Records 11 12 12 12 13 13 13 14 15 16 Appendices Table-1.3. Lead-Acid Battery Maintenance Schedule Table-2. Flooded.2 5.3.3.3.6 5.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 5.5 5. Wet Cell.3.3 5. Vented Nickel Cadmium Battery Maintenance Schedule Technical LP 015 Page 4 of 16 .3.1 5.

Cadmium Description Technical LP 015 Page 5 of 16 .SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 ABBREVIATIONS LIST Abbreviation WI Ni-CD Work Instruction Nickel .

This cell is used as a representative for readings. Each year a new pilot cell is chosen.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 GLOSSARY OF TERMS Term UPS Pilot Cells Uninterrupted Power Supply After the initial charge or to begin an yearly cycle. Description Technical LP 015 Page 6 of 16 . for one year. choose a pilot cell from one of the lowest specific gravity and lowest voltage cells.

SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 SIGNS AND SYMBOLS NOT APPLICABLE Technical LP 015 Page 7 of 16 .

 Gases vented from the battery may contain acids that will remain as a residue on surfaces within the battery enclosure.  Prohibit smoking and open flames in the vicinity of the battery.  Consider any liquids on or near the battery as electrolytes until proven otherwise.  Avoid actions that might cause arcing in the immediate vicinity of the battery.0 Scope All station batteries used for battery charger and UPS on Shuweihat S1 site. 3. Wear personal protection equipment at all times. 2.0 4. such as jewellery.  Do not remove or block vents of any type of battery under charge.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 1. The development and implementation of Work Instructions (WI) governing the particulars for each and every system is the responsibility of the Electrical Lead Engineer.1 Procedure Considerations should include the following:- Safety Before you start. while working on or near electrical equipment.  Do not wear metallic objects.  Wear an ESD grounding wrist strap at all times while working on or near the battery.0 Policy It shall be the policy at the S1 Shuweihat power and Water plant that under normal operation. Responsibilities It shall be the responsibility of the Electrical Lead Engineer to identify the relevant systems and to establish the scheduled and condition based maintenance schedules.0 5.0 Purpose The purpose of this section is to outline the duties and responsibilities for routine operation and care of vented lead-acid batteries and Vented Nickel-Cadmium batteries used in battery charger and UPS. Neutralize suspected acid with bicarbonate of soda solution before touching any surface. here are some minimum safety precautions to observe during any battery maintenance  Use caution when working on batteries because they present a shock hazard. Technical LP 015 Page 8 of 16 . 5. Batteries should be checked on a regular basis. The Engineering Manager will provide the relevant resources within the maintenance section and review the extent and measures put in place from time to time.

Ref.2.01 volt reserved only for station battery duty and calibrate it as per the instruction in S1T LP 028. do not use a shop meter or electrician's general-use meter for battery voltages.  Maintenance on any battery known.01 volt with an accurate digital voltmeter. or suspected. This gas is 10 times more toxic than cyanide gas.1 Voltage Readings Technical LP 015 Page 9 of 16 . Each Shift (By operation) Check the voltmeter on the control panel to determine if the battery is being charged at the proper voltage. 5.2 Lead Acid Batteries Voltage readings should be taken in accordance with the following instructions. Provide a digital voltmeter accurate to 0. measure the voltages of the highest voltage cell and the lowest voltage cell of the battery to the nearest 0.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003  Check for the Hydrogen Detection alarm prior to entry into Battery Room or working on Batteries. check the overall float voltage across the battery terminals with an accurate digital meter and record. Quarterly Check the float voltage on all individual cells to the nearest 0. E. to be approaching thermal runaway should be performed by no fewer than two qualified technicians who are knowledgeable of batteries and trained in the safety precautions involved. If maintenance history indicates high temperature conditions. Note: Accurate voltmeters are critical for extending battery life. Adjust the battery charging voltage if necessary. may generate hydrogen sulphide gas. A.  Abnormal battery conditions. Monthly Check the pilot cell float voltage with an accurate digital voltmeter and record. F. B.. Adjust the battery charging voltage if necessary. When Taps Are Changed Check the voltage on the control panel when taps are changed on power or stationservice transformers.01 volt with an accurate digital voltmeter. This voltmeter must be treated with extra care. resulting from charging above 76degressC for example. The equalizing charge should be continued if the voltage difference between the two cells is more than that recorded for the initial charge. Monthly With the charger in service. Take these readings as rapidly as possible and record 5. During Equalizing Charge Just before terminating the equalizing charge. D. WI -Elect-ROU-058. C. exercise extreme caution. or if thermal runaway is suspected.

WI . Monthly Take the specific gravity reading of the pilot cell and record it. Rotate these cells so that readings are taken on different cells each quarter. Quarterly Record temperature readings of 10 percent of all the cells. If one or Technical LP 015 Page 10 of 16 . Annually Take specific gravity readings of every cell and record them. Ref. upper rows are warmer) the room ventilation may be inadequate. Ref. If the temperature spread of the cells exceeds 5 °C (i. D. take the specific gravity readings of every cell and record them. Record the room ambient temperature before cell temperatures are taken.. If possible. Annually If an accurate IR camera is available.2. 5. A. 5. while current is flowing. take the annual temperature readings of the cells just after camera calibration. After Equalizing Charge About 15 minutes after heavy gassing stops. however. the camera calibration must be checked at least once each year. B. use these readings to determine the pilot cells for the next year.e.Elect-RUN-059 Note: All specific gravity readings must be corrected to 25ºC before recording. B. C.2. etc.Elect-RUN-060. Do not attempt to take any specific gravity reading after adding water to a cell. If two cells with the lowest specific gravity (checked over the last one-eighth of the charging period) have not stopped rising. At the end of the yearly cycle. portable heaters. Monthly Record the pilot cell temperatures. Note: An accurate infrared (IR) camera may be used for temperatures.. continue the equalizing charge.3 Temperature Readings All cells of a battery should be at the same ambient temperature. i. The electrolyte takes several hours to mix after water is added. C.2 Specific Gravity Readings Specific gravity readings of vented lead-acid batteries must be taken in accordance with the following instructions.e. rotate the subject cells each quarter. take the temperature of the battery connections during a load or discharge test. A. Heat sources such as sunlight. WI .SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 them. must be blocked so they do not raise the temperature of individual cells. Quarterly Take specific gravity readings of 10 percent of the total number of cells and record them.

WI . Check for operation and cleanliness of body wash station. The readings should be on the order of a few micro-ohms (less than 100). B. and cabinets.5 Visual Inspections Visual inspections are made to assess the general condition of the battery. Check for a full gallon of labelled neutralizing solution.2. If any connection resistance has increased more than 20 percent. and retest.3 Nickel Cadmium Batteries The principles of operation. from -40 to +60 ºC. 5.3. and battery room. Check for corrosion at terminals.2. Check the ambient temperature and make sure ventilation devices (fans and vents) are operable. their temperatures will be higher than the other connections. Nickel cadmium cells are resilient to both overcharge and undercharge and may even be recovered if they go into polarity reversal. Check all the electrolyte levels and correct if necessary. Ref. record the resistance of each connection. face shields. Check for availability of insulated tools and utensils so short circuits can be avoided. Check for electrolyte leaks and cracks in cells. and safety equipment. WI . Ref.Elect-ROU-058 A.Elect-PM-061. connectors. and take corrective action if any are found. Check for a class C fire extinguisher and check that it has been inspected and tested according to schedule. retorque the connections. load test the entire battery bank as outlined in the work Instruction at 5-year intervals.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 more of the connections are loose or dirty. etc. battery room. mounting rack. apply no-ox grease.1 General Technical LP 015 Page 11 of 16 . Check the hydrometer for cleanliness and cracking of rubber parts. After Installation Using an accurate micro-ohm meter.6 Capacity Test to Determine Replacement To establish whether a battery is nearing the end of its useful life. This test should be repeated annually if the capacity has dropped below 90 percent. Monthly Check for general cleanliness of the battery. High temperatures do reduce service life but not as severely as lead cells. gloves. With proper maintenance. Check for availability and condition of all safety equipment. WI -Elect-PM-062. and care of nickel-cadmium (Ni-cad) batteries are different than those for lead-acid batteries. racks. aprons. and operability of eyewash station or portable eyewash equipment. Annually Repeat resistance checks of the connections checked in step A above and compare values. They may be used in a wide temperature range. clean. Ref.4 Contact Resistance Readings A. 5. service life may be expected to be as long as 25 years. 5. maintenance. 5.2. 5.

Check for electrolyte leaks and cracks in cells and take corrective action if found. Monthly Check for general cleanliness of the battery.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 5. Change this cell each year. B. Adjust the voltage if necessary. WI -Elect-ROU-065 A.Elect-ROU-065. 5. Read the voltages with the digital voltmeter and record them. Ref. A. WI . Quarterly Check and record the electrolyte temperature of the pilot cell. Take the voltages while on float and compare with previous readings. Quarterly Read the pilot cell voltage and the overall battery terminal voltage while on float. mounting rack. Check the Technical LP 015 Page 12 of 16 . Never insert a thermometer or any tool ever used for other batteries into a Ni-cad cell. racks. E. and safety equipment.3 Temperature Readings Ref. D. check the voltage on the control panel and adjust the charging voltage if necessary. Check for corrosion at terminals. Adjust the panel voltmeter if necessary. C. battery room.2 Voltage Readings Voltage readings must be taken by an accurate digital voltmeter. and cabinets.Elect-RUN-067 A. Use only an alcohol thermometer reserved only for this battery. F. Monthly Check the accuracy of the panel voltmeter against the digital voltmeter by measuring the battery terminal voltage. WI .3. Mercury thermometers may break and cause sparking or an explosion. Choose a pilot cell from one with the lowest voltage for readings in the coming year. connectors. During Initial Charge Just before terminating the initial or equalizing charge. Every Six Months Record the voltages of every cell taken with the digital voltmeter. 5. measure and record the voltage of each cell with an accurate digital voltmeter.3.3. Ref. Each Shift (by operation) Check the voltmeter on the control panel to determine if the battery is being charged at the proper voltage.4 Visual Inspections Visual inspections are made to assess the general condition of the battery. When Taps Are Changed When taps are changed on power or station-service transformers. and battery room.

6 Battery Discharge Testing Ref. WI . gloves.5 Contact Resistance Readings Ref. 5. If any connection resistance has increased more than 20 percent. any information in its soft form such as pictures. record the resistance of each connection. 5. test sheets etc are to be linked to the Maintenance Management system for maintaining a history of the equipment.4 Records The routine maintenance plans (PM’s) for each Battery Bank shall be setup in the Maintenance Management System (MAXIMO) and that shall trigger any frequency based or condition based maintenance. retorque the connections. Technical LP 015 Page 13 of 16 . etc. apply no-ox grease. Check for a full gallon of labelled neutralizing solution (20 ounces of boric acid per gallon of distilled water) and operability of body wash/eyewash station or portable eyewash equipment. clean. Annually Repeat resistance checks of the connections checked in step A above and compare values. After Installation Using an accurate micro-ohm meter. reports. The readings should be on the order of a few micro-ohms (less than 100). Check for availability of insulated tools so short circuits can be avoided. B. 5. For details. A battery capacity of 90 percent or less than rated capacity indicates that the battery is reaching the end of its service life. Where reasonably practical. A. refer to the above WI. Check for availability and condition of all safety equipment. Replace the battery as soon as possible after the capacity falls to 75 percent.Elect-PM-068. aprons. Perform capacity discharge tests annually after the capacity falls to 90 percent as revealed in the 5-year test.3. WI . and retest. face shields.SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 ambient temperature and make sure ventilation devices (fans and vents) are operable.Elect-PM-069 Perform this test every 5 years. Check the charger for current and voltage output.3.

SHUWEIHAT O&M LIMITED PARTNERSHIP Document Type: LOCATION TECHNICAL PROCEDURE Revision: 0 Print Date: 30 April 2013 Manual: Title: Document No CARE AND MAINTENANCE S1 T LP 015 OF BATTERIES Review Date: 16 December 2005 Issue Date: 17 December 2003 APPENDICES Technical LP 015 Page 14 of 16 .

Technical LP 015 Appendix A Page 15 of 16 . Flooded. Wet Cell. Lead-Acid Battery Maintenance Schedule Maintenance New Battery Visual Inspection Battery Float Voltage Cell Float Voltage Sp.2.Table-1. Fire Extinguisher etc.5) 3-Month Annual 5-Year Panel Meter Float Voltage Battery Terminals with Digital Voltmeter Pilot Cells with Digital Voltmeter Pilot Cells Pilot Cells All Cells with Digital Voltmeter 10 Percent of All Cells 10 Percent of All Cells Compare Panel Meter to Digital Voltmeter All Cells All Connections Yearly Capacity Capacity Test if 5 year Discharge Test<90 percent Test Wash Eqpt. Gr Readings Temperature Readings Contact Resistance Battery Testing Check Safety Equipment All Connections Acceptance Test After 1 week All Cells with Digital Voltmeter All Cells Shift Monthly Visual (see 5. Protective Clothing.

Vented Nickel Cadmium Battery Maintenance Schedule Maintenance New Battery Shift Monthly 3-Month 6-Month Annual Visual Inspection Battery Float Voltage Panel Meter Float Voltage All Cells with Digital Voltmeter Electrolyte Level Check Panel with Digital Voltmeter Battery Voltage All Cell Voltages Check Oil Level Cell Float Voltages Pilot Cell with Digital Voltmeter Pilot Cells Temperature Readings Inter cell Connections Battery Testing Torque to Specs.Table-2. Acceptance Test After 1 week Re torque to Specs. Capacity Tests if 5 Year Test <90 Percent Technical LP 015 Appendix B Page 16 of 16 .