Maintenance & Management of

DC System
&
DC FAILURE CASE STUDIES
MUNISH MISHRA
DGM(OS-ELECT)
 INTRODUCTION
• TYPES IN USE.
• MAINTENANCE PRACTICES TO
ENSURE HEALTHINESS.
• DC FAILURE AT JHAJJAR.
• DC EQUIPMENT FAILURE AT
FARAKKA.
• DC EQUIPMENT FAILURE AT VALLUR.
 TYPES
• LEAD ACID (TUBULAR , PLANTE)
• VRLA.
• NICAD.
Daily

1. DCDB Checking of DCDB P-E, N-E & P-E: Immediately attend DC

P-N voltage for earth fault in Main N-E: earth fault.
DCDBs of units & Switchyard.
P-N:
2. DC Trickle / Float charging Current O/P Adjust float voltage if
Charger (1.4mA/Ah for Lead Acid Plante current: & required
2.0mA/Ah for Ni-Cd)
3. 4. Battery Checking of pilot cell* voltage p-n: 1) Adjust float voltage
(2.25 ± 0.02V at 20-35degC for if
Lead Acid & 1.4-1.42V for Ni- required.
Cd) 2) Equalizing charge if
required

Checking of pilot cell* specific Sp.Gr Equalizing charge if

gravity (not applicable for Ni- required
Cd & VRLA) (Sp Gr 1.200 ±
0.005 at 27deg C)
 Weekly

Battery Checking of Electrolyte level and OK/NOT 1) Replace cracked cell

5. 6. any spillage / crack cells. OK 2) Add DM water as
7. per
manufacturer’s
instructions

General appearance and OK/NOT 1) When excessive dirt

cleanliness of the battery and
battery area.
OK deposition is noted on
cells or connectors wipe
with clean wiper.
2) Identify the source /
cause of dirt ingress &
rectify the same.

Any evidence of sulphation / Cell no Remove sulphation and

corrosion at either terminals or apply petroleum jelly.
connectors Take appropriate action
as per manufacturer’s
instructions
8. Battery Condition of ventilation OK/NOT Rectify problem
Room equipment OK immediately.
 Sl No Equipment Action Record Corrective Action
9. 10. Availability of tap water/safety OK/NOT shower in Rectify problem
Battery room OK immediately.

Ambient temperature Temp:

11. DC drives Trial run of DC drives OK/NOT Oprn dept to record & OK
report abnormality

Monthly: Following activities are to be carried out in addition to the activities mentioned in daily & weekly maintenance schedule.

DC Charger Charger output current and voltage O/P voltage: Adjust float voltage set
12. O/P current: point if required

13. Battery Voltage of each cell and total p-n: battery terminal voltage. 1) Adjust float voltage
if required.
2) Equalizing charge if
required
Quarterly: Following activities are to be carried out in addition to the activities
mentioned in daily, weekly & monthly maintenance schedule.

14.
Battery Specific gravity of each cell (not applicable for Ni-Cd & VRLA)
Cell no:
Sp.Gr: Equalizing charge if required

15.
Temperature of electrolyte representative cells (suggestion: take
temperature in cells number 6, 12, 18, 24 . . . . . . . . . . . ) Cell no:
Temp: When cell temperature deviates more than 3’C from each other (or
average) during a single inspection, determine the cause and correct
Half yearly (during opportunity shutdown)
16. Battery Boost Charging of battery sets for Cell no: For Ni-Cd battery refer
Ni-Cd battery only Voltage: Cl. 5.0 Sl No B-6

17. DC system Load testing of DC System on Terminal Equalizing charge if

running of all DC drives for at voltage of required
least one hour, keeping charger battery
off & checking of healthiness. set after
one hr.

18. DCDB Checking for AC/DC mixing in OK/NOT Immediately attend to

Main DCDBs of units & OK rectify the abnormality.
Switchyard.