LECTURE ON BATTERY AND BATTERY CHARGER AT EHV S/S

By Er.R.K. Malviya,S.E.400kV Bina

Dt. 25-03-2015
----------------------------------------------------------------------------------------------------------------------------

BATTERY IS CONSIDERED TO BE THE HEART OF THE POWER PLANT AND

SUBSTATION

The Battery in a Power House /Sub-Station provides the ultimate and final Back up power for
operating emergency equipments , which protect the Generators/ Emergency Pumps/
Transformers/ Lines etc.

DC Power for operation of all switchgears ( i.e. C.B.) Protection Relays , Indicating lamps ,
Facia and scada system.

Power for emergency lighting within the generating station / Sub Station Building .

Uninterrupted power for controlling equipments / instruments / C& R panels UPS system.

Power for vital communication equipments ( PLCC) .

WHAT HAPPENED IF THE BATTERY FAILS IN AN EMERGENCY

The emergency pumps will not operate which could lead to seizure of the rotor bearings.
Switch Gears associated to Generators/ Transformers / Lines may not trip which could leads to
equipments damage and long interruption of power.
Unaccounted associated loss in industry/ production / finance / trade and standing of public life.
Failure of power back up in PLCC will delay restoration / normalization of supply.

Therefore the single most important reason for using Battery for power sector application is
Reliability and Reliable standby power source for delivering power as and when called at full
capacity to any point of time in its service life.
The predictability of Battery is its Health, impending failure, expected time of replacement and
time test feature.

CHOICE OF BATTERY PUT ON STANDBY APPLICATION DEPENDS UPON THE

FOLLOWING FACTORS.

1. PRIMARY

(a)Current Load
(b)Back up time
(c) Min. Voltage requirement of the system .

2.
(a) Expected frequency of discharge
(b) Any special charging requirement
(C) Any special environment requirement ( Op. Temp.)
Page 1 of 7
(d)Any special maintenance requirement.
(e)Any space limitation.

LEAD ACID BATTERIES :-

Of the all available storage batteries in the market , lead acid is the most economical and
common due to available of basic raw material, lead being cheep and easy in process. On the
other hand its scrap material is reusable by 90 % .
Lead acid cells give a high voltage (2V) per cell in relation to other battery. Thus for example 52
Cells of lead acid would be equivalent to 93 cells of Ni/Cad in terms of discharge voltage.
Lead acid system are most versatile in terms of discharge duty, they can supply very high
currents on instant demand at constant voltage and at the same time are also capable of
providing low current for extended period.
Lead acid battery can supply power over a wide range of temp. i.e. 40-50 degree.
Charge-Discharge cycling reversibility is very good
Lead acid batteries is standby/float application can operate within a narrow voltage range for
charge-discharge say 2.2 Vpc to 1.93 Vpc. Maintaining over 80 % state of charge.
Over 90 % of the total metal of a lead acid battery can be recovered at the end of its useful life,
this makes it one of the best power system back up which can operate with min. depletion of
scares resources.

CONSTRUCTION REATURE:-

There are two electrodes in each battery , One is positive plate which is cast from ultra high
pure lead. The basic surface area of each plate is vastly enhanced by the lamellar construction,
which results in an effective surface area which is about 12 times that of its geometric area. The
negative plate is cast with low antimony load alloy. The positive and negative plates are
interleaved and insulated from each other by rigid PVC separators.
Although there is no external paste or oxide incorporated in the positive plate instead a part of
the grid metal itself is electrochemically converted into the positive active material . Infect during
service the positive active material is continuously regenerated on the grid surface. By virtue of
large surface area the thickness of the active material film is smaller than conventional type as a
result of which the current path through the active material is considerable less than that of any
of the conventional type. High surface area also improves the charge acceptance of cells
comprising to any conventional type.
It does not have any leachable impurity in the positive plate. The negative plate potential and
the total back emf of the cell remains very steady throughout its life . This together with the
feature of continuous regeneration of positive active materials maintains the charge discharge
profile very steady.
The medium of electrolyte in the battery is sulfuric acid.

HOW LEAD ACID BATTERY WORKS –

Positive Negative Electrolyte Positive Negative Water

Pb O2 + Pb + 2H2 SO 4 === PbSO4 + PbSO4 + 2 H2 O

Charging Discharging

Page 2 of 7
INSTALLATION AND FIRST CHARGING OF BATTERY :-

(i) Receipt and Storage :-

(a)After receipt of Battery according to voltage rating ( 110 Nos. for 220 Volt , 55 Nos. for 110
Volt and 24 No. 48 Volts ) and accessories the total no. of packing’s should be first checked
and tally with delivery challan and order items.
(b)Whenever the cell supplied in packed condition unpack each case carefully without
imparting any damage to the contents of the packing. All cells should be removed carefully by
holding them in the bottom or in horizontal positioning. They should not be hold by terminals.
Any damage or shortage should be reported to the Co. promptly.
Normally following items are supplied with the battery set.
Apart from No. of cells and Qty. of acid Syringe type hygrometer , thermometer, cell tester ( 3-
0-3 Volt ) with leads , Rubber syringe ,Spanner, acid resisting funnel, Acid resisting jug,
Distilled water as per IS: 1069 , Petroleum jelly, Rubber gloves, Rubber apron, Eye wash
bottle, Nylone Brush and Rubber ankle gumboots are supplied.
( C ) The recommended self life of battery is Two years , therefore it must be used well in time.

(ii) Battery Room :-

Battery room must have sufficient ventilation to disperse the gases produced when the
batteries are on charge, Exhaust fans should be provided in the room having capacity to
change air six times per hr. floors and walls of the battery room should preferable have acid
resistant coating.
When Battery are installed in cubicles sufficient clearance should be allowed between the cells
and cubicle walls to prevent any short circuit.
Warning signs should be put on the walls indicating dangers of explosion in using naked
flames for smoking inside the battery room.
The layout of the Cells should be such that the end polarities of the battery are physically
separated from each other to prevent accidental shorting of these terminals.
Suitable stands/still ages should be provided for the support of the cells and should be
arranged so that each cell will be easily accessible for inspection ,topping up etc.
Location of take off for easy connection to the charging equipment / load.
The positive end of the battery has to be connected to the positive output of the charger and
negative end of the battery to the negative of the charger.
Before connecting up apply an even coating of petroleum jelly to the bolts, nuts, washers,
connectors, and terminal pillars. All nuts and washers bolts should be connected firmly with
spanner.
Finally check again that the cells are connected in the correct sequence i. e. in series
Charging a cell of the whole battery in the wrong direction will cause permanent damage.

ELECTROLYTE :-

Battery grade sulphuric acid confirming to IS : 266-1993 diluted with distilled water to
specific gravity 1190 +- 0.005 at 27 Degree required for filling the cells. This is normally
supplied ready to use and if not it should be diluted to battery grade . For this suitable vessel
for mixing the acid and water is lead lined wooden boxes . Due to considerable heat evolved
during this process , Glass or plastic containers must used , although jugs made of these
Page 3 of 7
 materials are ideal for handling dilute acid. While mixing acid , first put the water in vessel then
add the acid slowly and cautiously , stirring continuously and adding only a little at a time .
Never add the water to the strong acid since it will splash dangerously.

Sufficient quantity of battery grade sulphuric acid and a little of spare must be kept ready at
site for the initial filling of the cells. The app. Qty. of acid per cell is given in the data. Use only
porcelain glass or plastic jug for filling the cells, metallic vessels must never be use.
Fill the cell to the Max. level line on the container and leave to allow the acid to soak into the
separators and plates for a period of 8-12 hrs. The plates will absorbed some electrolyte and
electrolyte level will drop. Restore the electrolyte level at the end of 12 hrs. period by adding
more acid of same grade.
After first filling in all the cells following are to be ensured prior to commencement of initial
charging :-

(a) Checking of correct polarity of all the cells connected in the circuit.
(b) Recording of individual cell voltage , gravity and Temp.
(c) Recording of total battery voltage and compare with sum of total of individual voltage.

Before filling of electrolyte in the Battery we must ensure healthiness and suitability of Battery
charger , A.C. mains , therefore load test on Battery charger must be done .The initial charging
must commence within 24 Hrs. of electrolyte filling.

Temp. correction of electrolyte – SG 27 == SG t + 0.0007 (t-27)

Where SG 27 = specific gravity at 27 0 c
SG t = specific gravity at t0 C
t = electrolyte temp.

FIRST CHARGE :- The Charging of Battery should be started at the rate specified by individual
make and type. It is roughly 6.5 % to 10 % of rating. Soon the battery gravity will raise and
voltage will increase. The Battery will start gassing and Temp. may also raise. The current
should be reduced he finishing rate as soon as the gravity for three consecutive Hrs. remains
constant and total in feed AH has been completed as per specification of Manf. If the voltage
or temp. of the battery increased more than 2.75 Volt or 50 Degree the charging rate may be
reduced and time in feed amy be increased , but total in feed will remain unchanged. During this
period every 4 hrs. reading of Voltage / Current/ Gravity/ Temp. should be recorded. At the end
of cycle ( after 80 % AH ) Hr. reading should be recorded. Normally the total in feed AH is 2.5
times to 3 times of rating and take about 60 to 75 Hrs. During this period hourly reading of any
pilot cell may be recorded.

COMPLETION OF CHARGE :-

First charge at finishing rate should be continued until all the sign of completion of charge are
observed.

(a)Specific Gravity - For some hrs after starting the charge the specific gravity of lectrolyte will
fall after which it will begin to raise slowly and continue to raise throughout the charge until
finally it ceases to raise and remain constant.

(b)VOLTAGE – The cell voltage at the bigening of the charge will be little over 2 Volt and will
raise during the charge finally attaining a steady state and may be between 2.65 – 2.75 Volt per
cell depending upon electrolyte temp. the base temp for Battery is 27 Degree.

Page 4 of 7
(c)GASSING – the reduction of current during charge as mention above is to limit the amount of
gassing , but at the end of charge all the cells should gas freely and vigorously. If any cell fails
to gas freely or gravity is low , it should be monitor separately and corrected it till it becomes as
good as others.

(d) ADJUSTMENT OF GRAVITY – With the electrolyte at the max. level the corrected fully
charged gravity is 1200 at 27 Degree with +/- 0.005 tolerance. If any deviation it should be
suitable adjusted by adding distilled water or remove some electrolyte and add of high gravity
acid, But when the gassing and charging is under progress.

(e)While charging, if due to any reason the charging is suspended, in any case it should not be
more than 12 Hrs. and total AH in feed should not be less than 50 %.

(f)The performance of any battery during its service depends upon to a great extent how
completely the initial or first charging is carried out.

DISCHARGE :-

(a)The Battery which has been given first charge is allowed to stand on open circuit for not less
than 12 Hrs.- 24 Hrs. thereafter discharge the battery at 10 Hrs. rating through a variable water
load . The discharge shall be stopped when the closed circuit voltage acr0ss the battery has
fallen 1.85 Volt X N Cells. Or when the voltage of any cell has fallen to 1.7 Volt. Whichever is
earlier.

(b)Recharge the battery at a constant recharge current till voltage of the cell reaches 2.35 to 2.4
Volt per cell and then at finishing rate till voltage is reached 2.55 to 2.65 Volt per cell and
specific gravity 1200 +/- 0.005 .Both remain constant for three consecutive hrs.

(c )Two discharge/ Charge cycles may be given depends upon performance of Battery in first
discharging. Maintain the electrolyte level as per indication during recharging process. Now the
battery is ready to put into service.

FLOAT CHARGING OF BATTERY :-

(a)When the battery is put into service, it can not be allowed to remain on open circuit as it
requires to compensate its internal losses. Unless the internal losses are continuously
compensated , the battery may not posses its full energy at a time when it is most essentially
required ,Therefore to keep the battery on trickle/float charge continuously. The
approximately value of the trickle charge current is 1 mA. Per AH. , therefore for 200 AH
Battery set the trickle current for new battery is 0.2 A. Too much trickle charge current is
indicated by gassing of plates , which reduces the battery life. Whereas sickle appearance of
battery by falling of specific gravity or voltages of pilot cell . therefore trickle current is also
required to correct when battery becomes older and older.
(b)Therefore to keep the battery at correct float voltage / trickle current the Battery charger
should have auto/ manual control. Now a days very precise charger to select both voltage/
current at any desire level in auto/manual mode are available , by which the required level as
desire by battery is in feed.
(c) The float charger is also set to meet the load of the DC system at desire voltage.
(d)During sudden demand of DC load say in case of operation/ control or supply failure for long
period , the Battery will supply the additional load even if float charger is on. Therefore after
such operation the battery may be put on Boost charging.

Page 5 of 7
BOOST CHARGING OF BATTERY :-

(a)Boost charging of the battery is needed weekly ( during maintenance, distilled water topping
up ) / major period supply failure or load test . The battery is put on boost charging at rated
current for few hrs. depends upon battery condition/ Gravity/Voltages etc .During boost
charging the voltages of battery may go up , therefore drooping diodes/ tap battery cell may be
used depends upon requirement. The battery charger is built with the feature of dropper
diodes of 8-10 volts. The diodes may be selected in 3-4 steps as per requirement of load
supply voltage. In this case the load voltage will remain steady and will not harm electronic
sensitive components. The same feature is available by using different taps of battery. In the
110 Volt battery set 48-50-52-55 cells are selected and connected to battery charger. Which
upon selection during boost charging gives an load voltage from the selected tap. Whereas
during supply failure or change over period the min. tap cell are available.

MAINTENANCE OF BATTERY :-

Daily :-

(a) Daily reading such as voltage / gravity of pilot cell ( 5 %) should be recorded. The floating
voltage of the charger across the battery and trickle current should be noted .
(b)The cell containers, stands, insulators, connectors, vent plugs, terminals have to be
cleaned every day.
(c) In order to ensure that the full battery is available across the DC load tarminals, it is
necessary to switch off the float charger , for a one minute duration everyday , this will
confirm that thereis no open circuit anywhere.

WEEKLY :-

(a)Check the electrolyte level in each of the cells to ensure the electrolyte level to correspond
to the red mark on the float guide. If the level is lower , top –up with pure distilled water (
IS: 1069).
(b)Measure the Voltages and specific gravity of each cell .
(c) Boost charge the Battery if needed.
(d)Check Physically any abnormality in the battery charger.
(e)Ventilation / exhaust fan in the battery room. Cleaning of room.

MONTHLY :-

(a)Only when it is found that the specific gravity are not uniform ,( more than 10 points)
discharge the battery for a short duration of 15-30 min. at 10 Hrs rate or lower rate ( say 2.5
% ) and then recharge thereafter at equalizing rate, the voltage may go up to 2.35 -2.4 Volt .
Find the reason of differences.
(b) Check the tightness of connecting strips. Apply petroleum jelly on the terminals.
( c ) Check the tightness and any deposition on the lugs of cable connection in battery
charger / battery.

(i) Apart from above yearly calibrate the measurement meters of battery/ charger . Painting by
acid resistance paint. Maintenance of exhaust fans. Etc.
(ii) Checking of charger , healthiness of components, dust cleaning etc. its protection check are
also required to be carried out.
(iii) Testing of battery for its capacity test for old Battery set 10 Hrs. rating and terminate the
test when any of the cell voltage reaches 1.85 Volt.

Page 6 of 7
 Actual capacity of battery at 27 0 C Ct * 0.43 (27-t)
= Ct + ---------------------------------
C27
100
Where C27 actual cap. of battery at 27 0 degree
C t Battery cap. At av. Temp.
t av. Temp. of battery
0.43 variation factor

BATTERY CHARGER
Instruction for installation & commissioning of Battery charger

INITIAL INSPECTION :- Inspect the package for external evidence of damage and informed the
Co. After unpacking unit inspect through visual check to detect any transit damage to any
component on the front panel or inside the cubicle. If any loose or broken connections are
noticed set them correct.

MECHANICAL INSTALLATION :- The panel are free standing steel structure and should be
installed in dust free well ventilated place leveled place as per foundation plan. Clean the
equipment properly.

ELECTRICAL INSTALLATION :- Connect three phase AC input supply as per drawing.

Connect the earth to the panel. Push all the fuses, as they might have become loose in
transient. Check that all the PCB connections are properly placed in their correct position.

FLOAT CHARGER :- In every charger there is a float charger which can supply load as well
as internal losses of battery and keep the battery in healthy condition to feed instant load
demand all the time. The float charger has low current capacity with auto/ manual mode. The Dc
is driven from a three ph step down X-mer through full wave rectifier .Half of rectifier is by silicon
diodes and other half is thirstier controlled. All six thyristers also used . The out put current can
be finely and auto controlled by thyristers through firing card. Each rectifier is protected by
individual fuses. The float current and trickle current both can be read in a common meter
through a switch.

BOOST CHARGER :- Similarly to float charger the boost charger is having high DC current out
put for initial and boost charging of battery. The DC is driven from a separate three ph step
down X-mer through full wave silicon diodes. The current is controlled from a motorized variac
connected to X-mer with Auto/ manual mode. In boost mode to control load voltage four
different tap selector switch is provided , which connect different cells of a battery such as 45-
48-52-& 55 Nos.
A typical wiring diag. of statcon battery charger 110 Volt 200 AH and Battery set of HBL Nife is
attached for ref showing scheme and general arrangement. The different protection of a
charger are over voltage/ under voltage/ over current/ fuse failure/ earth leakage main supply
failure .

MILKY CHARGER :- A milky charger is nothing but a charger suitable for single cell charging at
rated current . Means it has out put DC voltage of 3.0 Volt and current rating 15 Amp in a 200
AH battery charger. When ever during service period of a battery if any cell is not charged in ckt
. or its voltage/ gravity is not make up, it requires to bring out from service and charge it
separately by milky charger just like battery set.

Page 7 of 7