Care of Batteries

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

AMENDMENT RECORD Revision Description Date Approved
Technical LP 015
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OVERALL TABLE OF CONTENTS

Amendment Record Overall Table of Contents Abbreviations List Glossary of Terms Signs And Symbols 1.0 2.0 3.0 4.0 5.0 5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.3 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
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Technical LP 015

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 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, Flooded, Wet Cell, Lead-Acid Battery Maintenance Schedule Table-2, Vented Nickel Cadmium Battery Maintenance Schedule
Technical LP 015
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ABBREVIATIONS LIST Abbreviation WI Ni-CD Work Instruction Nickel - Cadmium Description
Technical LP 015
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GLOSSARY OF TERMS Term

UPS Pilot Cells Uninterrupted Power Supply After the initial charge or to begin an yearly cycle, choose a pilot cell from one of the lowest specific gravity and lowest voltage cells. This cell is used as a representative for readings, for one year. Each year a new pilot cell is chosen.
Description
Technical LP 015
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SIGNS AND SYMBOLS
NOT APPLICABLE
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1.0
Policy
It shall be the policy at the S1 Shuweihat power and Water plant that under normal operation, Batteries should be checked on a regular basis.
2.0
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.
3.0 4.0
Scope
All station batteries used for battery charger and UPS on Shuweihat S1 site.
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. The development and implementation of Work Instructions (WI) governing the particulars for each and every system is the responsibility of the Electrical Lead Engineer. 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.
5.0 5.1
Procedure
Considerations should include the following:-
Safety
Before you start, here are some minimum safety precautions to observe during any battery maintenance Use caution when working on batteries because they present a shock hazard. Prohibit smoking and open flames in the vicinity of the battery. Avoid actions that might cause arcing in the immediate vicinity of the battery. Do not wear metallic objects, such as jewellery, while working on or near electrical equipment. Wear an ESD grounding wrist strap at all times while working on or near the battery. Gases vented from the battery may contain acids that will remain as a residue on surfaces within the battery enclosure. Wear personal protection equipment at all times. Consider any liquids on or near the battery as electrolytes until proven otherwise. Neutralize suspected acid with bicarbonate of soda solution before touching any surface. Do not remove or block vents of any type of battery under charge.
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Check for the Hydrogen Detection alarm prior to entry into Battery Room or working on Batteries. Abnormal battery conditions, resulting from charging above 76degressC for example, may generate hydrogen sulphide gas. This gas is 10 times more toxic than cyanide gas. If maintenance history indicates high temperature conditions, or if thermal runaway is suspected, exercise extreme caution. Maintenance on any battery known, or suspected, 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..
5.2
Lead Acid Batteries

Voltage readings should be taken in accordance with the following instructions. Ref. WI -Elect-ROU-058. Note: Accurate voltmeters are critical for extending battery life. Provide a digital voltmeter accurate to 0.01 volt reserved only for station battery duty and calibrate it as per the instruction in S1T LP 028. This voltmeter must be treated with extra care; do not use a shop meter or electrician's general-use meter for battery voltages. A. Each Shift (By operation) Check the voltmeter on the control panel to determine if the battery is being charged at the proper voltage. Adjust the battery charging voltage if necessary. B. When Taps Are Changed Check the voltage on the control panel when taps are changed on power or stationservice transformers. Adjust the battery charging voltage if necessary. C. During Equalizing Charge Just before terminating the equalizing charge, measure the voltages of the highest voltage cell and the lowest voltage cell of the battery to the nearest 0.01 volt with an accurate digital voltmeter. The equalizing charge should be continued if the voltage difference between the two cells is more than that recorded for the initial charge. D. Monthly With the charger in service, check the overall float voltage across the battery terminals with an accurate digital meter and record. E. Monthly Check the pilot cell float voltage with an accurate digital voltmeter and record. F. Quarterly Check the float voltage on all individual cells to the nearest 0.01 volt with an accurate digital voltmeter. Take these readings as rapidly as possible and record
5.2.1 Voltage Readings
Technical LP 015
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them. At the end of the yearly cycle, use these readings to determine the pilot cells for the next year.
5.2.2 Specific Gravity Readings

Specific gravity readings of vented lead-acid batteries must be taken in accordance with the following instructions. Ref. WI - Elect-RUN-059 Note: All specific gravity readings must be corrected to 25C before recording. Do not attempt to take any specific gravity reading after adding water to a cell. The electrolyte takes several hours to mix after water is added. A. Monthly Take the specific gravity reading of the pilot cell and record it. B. Quarterly Take specific gravity readings of 10 percent of the total number of cells and record them. Rotate these cells so that readings are taken on different cells each quarter. C. Annually Take specific gravity readings of every cell and record them. D. After Equalizing Charge About 15 minutes after heavy gassing stops, take the specific gravity readings of every cell and record them. If two cells with the lowest specific gravity (checked over the last one-eighth of the charging period) have not stopped rising, continue the equalizing charge.
5.2.3 Temperature Readings

All cells of a battery should be at the same ambient temperature. Heat sources such as sunlight, portable heaters, etc. must be blocked so they do not raise the temperature of individual cells. Record the room ambient temperature before cell temperatures are taken. Ref. WI - Elect-RUN-060. Note: An accurate infrared (IR) camera may be used for temperatures; however, the camera calibration must be checked at least once each year. If possible, take the annual temperature readings of the cells just after camera calibration. If the temperature spread of the cells exceeds 5 C (i.e., upper rows are warmer) the room ventilation may be inadequate. A. Monthly Record the pilot cell temperatures. B. Quarterly Record temperature readings of 10 percent of all the cells; rotate the subject cells each quarter. C. Annually If an accurate IR camera is available, take the temperature of the battery connections during a load or discharge test, i.e., while current is flowing. If one or
Technical LP 015 Page 10 of 16

more of the connections are loose or dirty, their temperatures will be higher than the other connections.
5.2.4 Contact Resistance Readings

A. After Installation Using an accurate micro-ohm meter, record the resistance of each connection. The readings should be on the order of a few micro-ohms (less than 100). B. Annually Repeat resistance checks of the connections checked in step A above and compare values. If any connection resistance has increased more than 20 percent, clean, apply no-ox grease, retorque the connections, and retest. Ref. WI - Elect-PM-061.
5.2.5 Visual Inspections

Visual inspections are made to assess the general condition of the battery, battery room, and safety equipment. Ref. WI - Elect-ROU-058 A. Monthly Check for general cleanliness of the battery, mounting rack, and battery room. Check for electrolyte leaks and cracks in cells, and take corrective action if any are found. Check for corrosion at terminals, connectors, racks, and cabinets. Check the ambient temperature and make sure ventilation devices (fans and vents) are operable. Check all the electrolyte levels and correct if necessary. Check for availability and condition of all safety equipment, gloves, aprons, face shields, etc. Check for a full gallon of labelled neutralizing solution, and operability of eyewash station or portable eyewash equipment. Check for operation and cleanliness of body wash station. Check for a class C fire extinguisher and check that it has been inspected and tested according to schedule. Check for availability of insulated tools and utensils so short circuits can be avoided. Check the hydrometer for cleanliness and cracking of rubber parts.
5.2.6 Capacity Test to Determine Replacement

To establish whether a battery is nearing the end of its useful life, load test the entire battery bank as outlined in the work Instruction at 5-year intervals. This test should be repeated annually if the capacity has dropped below 90 percent. Ref. WI -Elect-PM-062.
5.3
Nickel Cadmium Batteries

The principles of operation, maintenance, and care of nickel-cadmium (Ni-cad) batteries are different than those for lead-acid batteries. Nickel cadmium cells are resilient to both overcharge and undercharge and may even be recovered if they go into polarity reversal. They may be used in a wide temperature range, from -40 to +60 C. High temperatures do reduce service life but not as severely as lead cells. With proper maintenance, service life may be expected to be as long as 25 years.
5.3.1 General
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5.3.2 Voltage Readings

Voltage readings must be taken by an accurate digital voltmeter. Ref. WI -Elect-ROU-065 A. Each Shift (by operation) Check the voltmeter on the control panel to determine if the battery is being charged at the proper voltage. Adjust the voltage if necessary. B. When Taps Are Changed When taps are changed on power or station-service transformers, check the voltage on the control panel and adjust the charging voltage if necessary. C. During Initial Charge Just before terminating the initial or equalizing charge, measure and record the voltage of each cell with an accurate digital voltmeter. Choose a pilot cell from one with the lowest voltage for readings in the coming year. Change this cell each year.
D. Monthly
Check the accuracy of the panel voltmeter against the digital voltmeter by measuring the battery terminal voltage. Adjust the panel voltmeter if necessary. E. Quarterly Read the pilot cell voltage and the overall battery terminal voltage while on float. Read the voltages with the digital voltmeter and record them. F. Every Six Months Record the voltages of every cell taken with the digital voltmeter. Take the voltages while on float and compare with previous readings.
5.3.3 Temperature Readings

Ref. WI - Elect-RUN-067 A. Quarterly Check and record the electrolyte temperature of the pilot cell. Use only an alcohol thermometer reserved only for this battery. Mercury thermometers may break and cause sparking or an explosion. Never insert a thermometer or any tool ever used for other batteries into a Ni-cad cell.
5.3.4 Visual Inspections

Visual inspections are made to assess the general condition of the battery, battery room, and safety equipment. Ref. WI - Elect-ROU-065. A. Monthly Check for general cleanliness of the battery, mounting rack, and battery room. Check for electrolyte leaks and cracks in cells and take corrective action if found. Check for corrosion at terminals, connectors, racks, and cabinets. Check the
Technical LP 015 Page 12 of 16

ambient temperature and make sure ventilation devices (fans and vents) are operable. Check the charger for current and voltage output. Check for availability and condition of all safety equipment, gloves, face shields, aprons, etc. 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. Check for availability of insulated tools so short circuits can be avoided.
5.3.5 Contact Resistance Readings

Ref. WI - Elect-PM-068. A. After Installation Using an accurate micro-ohm meter, record the resistance of each connection. The readings should be on the order of a few micro-ohms (less than 100). B. Annually Repeat resistance checks of the connections checked in step A above and compare values. If any connection resistance has increased more than 20 percent, clean, apply no-ox grease, retorque the connections, and retest. For details, refer to the above WI.
5.3.6 Battery Discharge Testing

Ref. WI - Elect-PM-069 Perform this test every 5 years. A battery capacity of 90 percent or less than rated capacity indicates that the battery is reaching the end of its service life. Perform capacity discharge tests annually after the capacity falls to 90 percent as revealed in the 5-year test. Replace the battery as soon as possible after the capacity falls to 75 percent.
5.4
Records
The routine maintenance plans (PMs) for each Battery Bank shall be setup in the Maintenance Management System (MAXIMO) and that shall trigger any frequency based or condition based maintenance. Where reasonably practical, any information in its soft form such as pictures, reports, test sheets etc are to be linked to the Maintenance Management system for maintaining a history of the equipment.
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APPENDICES
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Table-1, Flooded, Wet Cell, Lead-Acid Battery Maintenance Schedule
Maintenance New Battery Visual Inspection Battery Float Voltage Cell Float Voltage Sp. 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 5.2.5)
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; Protective Clothing; Fire Extinguisher etc.
Technical LP 015 Appendix A
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Table-2, 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. Acceptance Test After 1 week
Re torque to Specs. Capacity Tests if 5 Year Test <90 Percent
Technical LP 015 Appendix B
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Care of Batteries

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SHUWEIHAT O&M LIMITED PARTNERSHIP

Care and Maintenance of Batteries

Prepared Status Approved Name: G.Chaturvedi

Reviewed Frank Siegmund Ian Coupland

Date: 22 November 2003 29 November 2003

17 December 2003 Page 1 of 16

SHUWEIHAT O&M LIMITED PARTNERSHIP

AMENDMENT RECORD Revision Description Date Approved

SHUWEIHAT O&M LIMITED PARTNERSHIP

OVERALL TABLE OF CONTENTS

SHUWEIHAT O&M LIMITED PARTNERSHIP

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.4

SHUWEIHAT O&M LIMITED PARTNERSHIP

ABBREVIATIONS LIST Abbreviation WI Ni-CD Work Instruction Nickel - Cadmium Description

SHUWEIHAT O&M LIMITED PARTNERSHIP

GLOSSARY OF TERMS Term

SHUWEIHAT O&M LIMITED PARTNERSHIP

SIGNS AND SYMBOLS

SHUWEIHAT O&M LIMITED PARTNERSHIP

SHUWEIHAT O&M LIMITED PARTNERSHIP

Lead Acid Batteries

5.2.1 Voltage Readings

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5.2.2 Specific Gravity Readings

5.2.3 Temperature Readings

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5.2.4 Contact Resistance Readings

5.2.5 Visual Inspections

5.2.6 Capacity Test to Determine Replacement

Nickel Cadmium Batteries

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5.3.2 Voltage Readings

5.3.3 Temperature Readings

5.3.4 Visual Inspections

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5.3.5 Contact Resistance Readings

5.3.6 Battery Discharge Testing

SHUWEIHAT O&M LIMITED PARTNERSHIP

Table-1, Flooded, Wet Cell, Lead-Acid Battery Maintenance Schedule

Monthly Visual (see 5.2.5)

Panel Meter Float Voltage

Compare Panel Meter to Digital Voltmeter

Technical LP 015 Appendix A

Table-2, Vented Nickel Cadmium Battery Maintenance Schedule

Check Oil Level

Cell Float Voltages

Pilot Cell with Digital Voltmeter Pilot Cells

Re torque to Specs. Capacity Tests if 5 Year Test <90 Percent

Technical LP 015 Appendix B

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