National Transmission and Despatch Company

(4th Technical Refresher Course)

Engr. Naveed Iqbal

Deputy Manager
220 KV G/S Daudkhel
 Types of Station Batteries
 Parts of batteries
 Types of Lead acid Batteries
 Specific Gravity
 Charging of Batteries
 Capacity of Batteries
 Maintenance of Batteries
 Safety
A battery is an electrochemical device which
converts chemical energy into electrical
energy.

Types of Station batteries

 Lead acid batteries
 Alkaline batteries
 LEAD ACID BATTERIES

MAIN PARTS OF LEAD ACID BATTERY

The main parts of lead acid battery are:

 Plates
 Terminals
 Separator
 Electrolyte
 Container
 A lead-acid battery uses a series of lead dioxide
plates for its positive (+) terminal and porous, soft
lead for its negative plates.
 All the plates are arranged alternately and submerged
in a solution of sulfuric acid and water.
 The positive plate's lead oxide is a compound of lead
and oxygen.
 Sulfuric acid is a compound of hydrogen and the
sulfate radical (SO4), so the acid's chemical
designation is H2SO4
TYPES OF LEAD ACID BATTERY:-
There are three types of lead acid battery
(i) Lead antimony batteries
(ii) Lead Planti battery and
(iii) Lead Calcium battery

But mostly Lead Antimony batteries are used in Grid

Station because these batteries are suitable for
cycling i.e. for frequent charging/discharging and
also these batteries are less expensive.
 SPECIFIC GRAVITY (S.G) OF LEAD ACID
BATTERIES:

 S.G is the ratio of Density of substance to

the Density of water OR
S.G = Weight of substance / Weight of
equal volume of water.
 S.G of Water = 1
Concentrated H2SO4 =1.834
 S.G of all lead acid batteries used in Grid
Stations is from 1200 to 1220 at 77F or
25C electrolyte temperature.
 When preparing new electrolyte, ALWAYS
ADD LITTLE QUANTITY OF ACID IN LARGE
QUANTITY OF WATER. NEVER ADD WATER
IN THE ACID.
 HOW TO TAKE S.G READING WITH HYDRO
METER:

 When taking S.G reading with hydro meter

its bulb should be squeezed gently but fully
several times before taking sample.
 The electrolyte taken from a cell must be
returned to same cell.
 S.G should not be taken if there is gassing
and at least two hours should be elapsed
when water was added in order to give time
so that water has been mixed with the
electrolyte completely.
Temperature effect on S.G:
 S.G varies with temperature inversely at the
rate of 1 point for every 3F.
 Hence specific gravity reading must be
corrected to 77F electrolyte temperature.

Importance of S.G In Lead Acid Batteries

 S.G indicates the state of charge of a
battery.
 S.G tells when to put battery bank or cell on
equalize or boost charging.
 S.G tells whether the battery will deliver its
full rated ampere hour capacity or not.
 S.G tells about the condition/life of a
battery/cell.
 If S.G of any cell is found out of range from
1190 to 1235 at 77F electrolyte
temperature, it must be reported.
 When any cell is suspected to be very poor
then remove it from the battery bank
 Fully charge it
 Note its S.G
 Then leave it open circuited for 30 days
After 30 days……
 Check its S.G
 If its S.G has dropped more than 25 points
then this cell must be discarded
TERMINAL\ NOMINAL VOLTAGE

The terminal voltage of

 Lead Antimony battery = 2.15 v/cell.

 Lead Planti and Lead Calcium batteries = 2.17 v/cell.

Therefore the terminal voltage of 100 cells

 Lead Antimony battery 2.15100 = 215 volts

 Lead Calcium / Lead Planti battery: 2.17100 = 217 volts
 Voltage of a good condition battery also
varies with S.G. Voltage increases slightly
when S.G increases.
 NOTE: Voltage also tells about the state of
charge of the battery but the voltage itself
depends upon S.G.
Hence voltage is not an effective mean for
determining the state of charge of lead acid
batteries.
 Pilot cell:
 The poorest cell in the battery is called pilot cell.
 It has lowest S.G, lowest voltage and more sediments
at bottom.
Advantages of having a pilot cell in a battery are:-
 It tells about the state of charge and condition of
whole battery bank.
 It minimizes the labor and helps to maintain better
continuity of records.
 The electrolyte level of pilot cell must be maintained
on full mark all the times.
 DAMAGE CELL REPLACEMENT BY PARALLEL
CELL METHOD:
 In this method 6,8 or 12 volt battery is
connected across the number of cells of
battery, containing damage cell, whose
total voltage is same as that of battery
connected in parallel.
 Put new cell in its place and
 Disconnect 12v battery
 Procedure:
 Connect 12v or required voltage battery to
the station battery cell according to
correct polarity.
 Before making the final connection check
voltage between the two with D.C
voltmeter. This voltage must be nearly
zero. This is necessary to avoid any
sparking.
 Then complete connections
 Remove defective cell
 FLOAT OR TRICKLE CHARGING:

 Batteries are generally kept on float voltage

which is equal to the nominal voltage of
battery.
 For lead antimony batteries float voltage is
2.15 volts/cell and for lead Planti/lead calcium
batteries float voltage is 2.17 volts/cell.
 This voltage is sufficient to maintain the S.G. of
most of the cells at fully charged state.
 Float voltage must be as accurate to its
calculated value as possible because very
small changes in float voltage causes
considerable increase/decrease in charging
current and hence causing OVER
CHARGING/UNDER CHARGING OF BATTERY
WHICH ARE THE MAIN TWO FACTORS OF
REDUCING BATTERY LIFE.
 FLOAT VOLTAGE OF BATTERY is adjusted by
current limiting resistors provided to the rectifier.
But for this panel volt meter should not be relied
upon, so accurate volt meter should be used.
 CAUSES OF OVER CHARGING:
Over charging result when float voltage of
battery is more than its calculated value.
The main causes of over charging are:-
 Scrubbing of active material from plates
by Oxygen gas and acid fumes.
 Corrosion of +ve plates due to oxygen
and damage to –ve plates and separators
due to acid.
 Buckling i.e. turning of +ve plates which
may damage separators resulting in short
circuit of battery.
 INDICATIONS OF OVER CHARGING:
 Buckling of +ve plates (or both plates)
 Low electrolyte level.
 Corrosion of terminals (specially on +ve
plates side)
 High S.G. and low voltage.
 Cracking of +ve plate frame and
disintegration of +ve plate grid.
 Dark chocolate color on positive plates.
 Sediments at bottom of all cells.
 CAUSES OF UNDER CHARGING:
 Under charging result when float voltage of
battery is less than its calculated value. A
battery operation under charged for a long
time causes following:
 Sulphation of –ve plates mainly.
 Reduction in Amp hour capacity of battery.
 Rise in freezing point due to low S.G.
 INDICATIONS OF UNDER CHARGING:
 Sulphation
 Low S.G and voltage.

PURPOSE OF EQUALIZE OR BOOST CHARGING:

 In equalize charging battery is over charged
for a certain period for following purposes:-
 To ensure that S.G and voltage of each cell
will be raised to their maximum value.
 To ensure that every cell will gas free at
equal rate.
 To ensure that every plate in each cell will
be fully charged.
 WHEN TO PUT LEAD ACID BATTERY ON
EQUALIZE CHARGING:
For lead antimony battery :
 After every 3 months
For lead Planti and lead Calcium batteries:-
 After every 6 months.
 Whenever there is indication of under charging
i.e. indication of Sulphation or white powder
on plates.
 When the voltage difference between the
highest voltage cell and the lowest voltage cell
(or pilot cell) is more than 0.05 volts.
 When the S.G reading difference between
the present and previous value of the pilot
cell is more than 10 points.
 When the battery has performed heavy
discharge duty.
 After the prolong failure of charger (i.e.
rectifier).
EQUALIZE VOLTAGE FOR ALL LEAD ACID
BATTERIES IS 2.33 VOLTS/CELL
PROCEDURE:
 Add distilled water in all cells to the
maximum mark level, count number of cells
and calculate equalize voltage for them.
Then put battery on equalize charging for
24 hours.
 Sometimes pilot cell or any other cell may
be so badly deteriorated that it will take
long time for charging and it may effect the
life of other cells. So it must be removed
from the battery and charged separately.
 During equalize charging there is too much
gassing and hence explosive hazard will
always be present near the cells vent.
 So adequate ventilation of battery room
must be there and no flame be brought
near the cell vent.
 Moreover tightening and interconnections
work should not be done during this time
as it may produce spark resulting in
explosion.
 FRESHENING CHARGE:
 Freshening charge is given to that battery
which is received newly or which has
remained inactive for long period.
PURPOSE:
 To frame initial maximum S.G and voltage
readings of each cell for future reference.
 To choose pilot cell
 To fully charge all cells after long shipping
or inactive period.
 VOLTAGE FOR FRESHENING CHARGE IS SAME AS
THAT FOR EQUALIZE CHARING i.e. 2.33 VOLTS PER
CELL
Procedure:
 Procedure for freshening charge is same as
that for equalize charging but freshening
charge is continued up to 73 hours with a
break of half hour after every 24 hours.

 After 73 hours battery is put on float

charge.

 Then after 24 hour S.G and voltage reading

of each cell is taken and recorded.
 From these readings pilot cell is chooses. These are
the maximum initial S.G and voltage readings for
future reference.
 Then if during service S.G. of any cell is found
outside the range of 1190 to 1235, when corrected
to 77 F electrolyte temperature, should be
reported.
CAPACITY OF LEAD ACID BATTERY:

 Capacity of battery is rated in Ampere hours, mostly at 10

Hour rate.

 Capacity of battery is defined as the product of current which

it will deliver to discharge each cell to 1.75 volts and the time
for which it will deliver that current in doing so, keeping
electrolyte temperature at 77F.
 The battery may be discharge at any rate.
 TEMPERATURE EFFECT ON CAPACITY OF
BATTERY:
 Capacity of battery is directly proportional
to temperature i.e. it increases with the
increase of temperature and decreases with
the decrease of temperature.
 PURPOSE OF CAPACITY TEST:
 The main purpose of capacity test is to know about
the condition of a battery bank or cell.
 Initially capacity of a new battery is 85% of its rated
value. After first two years of service it increases to
100% and then gradually decrease with age till the
end of battery life.
 When capacity of battery becomes less than 75% of
its rated value at 77F electrolyte temperature then
the battery life ends and battery is replaced.
PROCEDURE:
 Top up electrolyte level in all cells to the
maximum marked level.
 Put battery on equalize charge for 24 hours.
 Calculate load for 10 hours discharge rate
DESCRIPTION OF FREQUENCY OF MAINTENANCE Standard
MAINTENANCE
DAILY/WEEKL QUARTER ANNU
Y LY AL
Battery room exhaust Yes _ _ Healthy
fan ventilation
Appearance of battery Yes No leakage of
electrolyte, clean
and no damage
Level of electrolyte Yes Near the max
level
Per cell voltage Yes >= 2 v

Specific gravity of Yes 1.100+-0.010

pilot cell at 25 C
Nominal voltage Yes >=rated voltage
110/220 vdc
Inter cell connectors Yes Correct torque,
Anti-corrosive
Vaseline applied
Exhaust plug cleaning Yes Clean
SAFETY:
 Approved rubber gloves, apron,
goggles and boots must be worn
during battery maintenance.
 Do not smoke in battery room.
 Put exhaust fan on before entering
into the battery room.
 Floor of battery room must be kept
clean, dry and free of grease and oils
etc. to avoid slipping.
 During equalize/freshening charging do not
bring any flame near cells and also do not
tight connection.
 When preparing electrolyte always add
small quantity of acid to large quantity of
water. Never add water to acid