Best Practice

SABP-P-002 Selection and Design of Battery Monitoring System Document Responsibility: CSD/ESD/Power Systems Unit 5 June 2006

Saudi Aramco DeskTop Standards

Table of Contents

1 2 3 4 5 6 7 8

Introduction..................................................... 2 References..................... 2 Definitions................................. 3 Safety Precautions .... 4 Types of Batteries... 6 Benefits of the Battery Monitoring System. 6 Battery Monitoring System Details.. 6 Battery Monitoring System Measured Parameters. 10

Attachment # 1 General System Diagram....... 15

Previous Issue: New Next Planned Update: 5 June 2011 Page 1 of 15 Primary contact: Faisal A. Al-Dubaikel on 873-6466

Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

Introduction 1.1 Purpose The purpose of this document is to introduce parameters & information that are usually provided by the battery monitoring system which will be useful for battery maintenance and replacement purposes. It will also establish guidelines for best battery monitoring system specifications and design. 1.2 Scope This best practice is intended to give general guidelines of the meaning of information & alarms obtained from the battery monitoring system and the best actions to be taken in case any alarm is generated. It is also intended to help in selecting and designing battery monitoring system. 1.3 Disclaimer This best practice is provided for the general guidance and benefit of Saudi Aramco engineers who would like to utilize BMS in their facilities. The use of the information or material contained here will not release operating facilities from their battery maintenance responsibilities. 1.4 Conflict with Mandatory Standards In the event of a conflict between this Best Practice and other Mandatory Saudi Aramco Engineering Requirements, the Mandatory Saudi Aramco Engineering Standards shall govern.

References This best practice is based on the latest edition of the references below, unless otherwise noted. 2.1 Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-350 Regular Maintenance and Testing for Industrial Stationary Batteries

Saudi Aramco Engineering Standards SAES-P-103 UPS & DC Systems

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

Saudi Aramco Material System Specifications 17-SAMSS-511 17-SAMSS-514 17-SAMSS-516 2.2 Stationary Storage Batteries Battery Charger/Rectifier Uninterruptible Power Supply System

Industry Codes and Standards Institute of Electrical and Electronics Engineers, Inc. IEEE 1491 IEEE Guide for Selection and Use of Battery Monitoring Equipment in Stationary Applications IEEE Recommended Practice for Maintenance, Testing, and Replacement of Vented Lead-Acid Batteries for Stationary Applications IEEE Recommended Practice for Maintenance, Testing, and Replacement of Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary Applications IEEE Recommended Practice for Installation, Maintenance, Testing, and Replacement of Vented Nickel-Cadmium Batteries for Stationary Applications Secondary Cells and batteries- Monitoring of Lead Acid Stationary Batteries - User Guide

IEEE 450

IEEE 1188

IEEE 1106

IEC 62060

Definitions AH capacity: The capacity assigned to a cell by its manufacturer for a given discharge time, at a specified electrolyte temperature and specific gravity. Battery Bank: One battery string or more than one string connected in parallel to form a battery bank. Battery Monitoring System: An unmanned fixed surveillance system for stationary Battery application. Battery String: Two or more cells connected in series to form a battery string. End of discharge voltage: The cell voltage at which the discharge is terminated. Normally, 1.75 VPC for lead acid and 1.10 for Ni-Cad.

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

Equalize charge: Charging the cell at elevated voltage to correct inequalities among battery cells. Float charge: Charging the cell at low voltage barely higher than the battery terminal voltage to keep the cell fully charged and compensate for self-discharge losses. Internal Cell Impedance: Any ohmic value of resistance, conductance or impedance which is based on the relation between the voltage and the current in a stationary battery which is used as an indicator of a battery's state of health. Load test: The discharge of a battery at a constant current or power to a specified end of discharge voltage. Nominal voltage: An approximated average cell voltage computed in the basis of 2.0 VPC for lead-acid and 1.2 VPC for Ni-Cad. Sulfation: a condition that happens in low state of charge in which lead crystals that are formed during discharge can become so large that they resist being dissolved during the recharge process. Specific gravity: The ratio of the density of electrolyte to the density of water at specific temp. (e.g., 25C). State of charge: The actual capacity of a cell, expressed as a percent of its rated capacity, that would be available if discharge were to occur. Thermal Runaway: A condition that is caused by a battery charging current that produces more internal heat than the battery can dissipate. This condition takes place in VRLA batteries and ultimately cases cell venting and permanent failure. Vented cell: A cell in which the products of electrolysis and evaporation are allowed to escape to the atmosphere as they are generated. These batteries are commonly referred to as flooded. VRLA: a cell that is sealed with the exception of a valve that opens to the atmosphere when the internal gas pressure in the cell exceeds atmospheric pressure by a preselected amount. VRLA cells provide a means for recombination of internally generated oxygen and the suppression of hydrogen gas evolution to limit water consumption. 4 Safety Precautions 4.1 The following personal protective equipment shall be available in the battery room before working with the batteries: a) Safety face shields and goggles
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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

b) c) d)

Safety aprons Acid resistance rubber gloves Eye washing facility (in case of acid contact with your eyes or skin, flush your with water for continuous 15 minutes and contact a physician immediately) Safety shoes Dry chemical fire extinguisher Thermometer Ample amount of neutralizing agent to neutralize electrolyte spillage Lead acid battery: Bicarbonate of soda, mixed 0.1 kg to 1.0 liter water Ni-Cd battery: Boric acid solution, mixed 50 gram to 1.0 liter water Or other suitable neutralizing agent recommended by the manufacturer for acid electrolyte spillage or the manufacturer of alkaline electrolyte spillage, whichever applicable.

e) f) g) h)

4.2

Use the following precautions when working on the batteries a) b) c) d) e) f) g) h) i) Use adequately insulated tools. Use caution when working on batteries since they represent electric shock hazard. Prohibit smoking and open flames, and avoid the chance of arcing in the immediate vicinity of the battery. Ensure the battery room ventilation is operational and the battery room temperature is maintained at 25C. Ensure unobstructed egress from the battery room area. Avoid wearing metallic object such as jewelry. Ensure that all connections to load test equipment include short-circuit protection. Neutralize static buildup just before working on a battery by having personnel contact nearest effectively grounded surface. Make sure that all vents of the cells/batteries are closed tightly before starting any battery testing process.

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

Types of Batteries There are basically three types of batteries that are used by Saudi Aramco: Vented Lead Acid Battery Valve Regulated Lead Acid Batteries (VRLA) Vented Nickel-Cadmium Batteries

Benefits of the Battery Monitoring System The battery monitoring system can perform many functions as listed in paragraph 7.2.1 on an automatic unattended basis. The advantage of battery monitoring system is its ability to continuously monitor, collect, store, report and analyze data. The parameters that are measured by the BMS vary from one manufacture to another. Batteries are one of the most critical equipment which are needed to provide power to critical facilities in case of power outage. The BMS can immediately identify any battery problem and initiate instantaneous alarms which will guarantee that batteries are always in good health when needed.

Battery Monitoring System Details The intend of this section is to give the user an idea of the best system specifications. This section is intended to give a general understanding and is not mandatory specifications. 7.1 General System Design There are different designs for battery monitoring system depending on the manufacturer. Attachment # 1 shows typical battery monitoring system design. The battery monitoring system should preferably have: a) b) c) Battery Monitoring Cabinet suitable for installation at the battery room. This cabinet should have local display where information can be obtained locally and should have local programming keypad. This cabinet should contain the processor and wiring connections for all battery voltage sense leads, current sensors, battery and ambient temperature sensors and alarm output connection. This cabinet should have RS 232 serial port for connecting a local laptop PC and also USB port. The laptop PC may be connected temporarily to the BMS unit on battery site for programming, calibration and viewing purposes.

d)

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

e)

Ability to transfer data to a central control room. Preferred communication method is Ethernet connection. Other communication method such as, RS 485 connection, short-haul modem or telephone modem can be considered upon availability and need. All required converters and switches that are required to transfer data should be provided. BMS Software which is installed at the central control room computer. All required wiring, leads, connectors and sensors for measuring the voltage, current and temperature.

f) g) 7.2

Battery Monitoring Systems Capabilities 7.2.1 The typical data that should be monitored, displayed and recorded by the battery monitoring system are: Overall Battery bank and/or string voltage Individual cell voltages Battery float, charge, discharge and equalize current Pilot cell temperature & ambient temperature Individual cell impedance including inter-cell connection resistance.

All of these parameters should be continuously monitored during normal operations and during all battery discharges. 7.2.2 7.2.3 The BMS should record all battery parameters specified above at the remote central computer, at user-defined intervals. The system should automatically display, store, and provide a printout of all alarm conditions that is outside the user defined pre-set limits, as and when they occur, at the Remote Central Computer. The system should provide and maintain a complete log of all discharge events, and an on-line display of battery voltage, individual cell voltages, battery string current, average ambient temperature, percent capacity discharged, and total current discharged in ampere-hours whenever the battery is in a discharge mode. In addition to the numerical display, it should provide a graphical display of the battery voltage and cell voltages versus time.

7.2.4

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

7.2.5

The system should store historical records of the internal cell impedance and inter-cell connection resistance of each cell. Compare the values to the baseline data for the specified type of cell. It should automatically provide trend warning when a cell starts to deviate from acceptable limits. The battery monitoring systems should preferably provide alarms in the plant DCS system to immediately acknowledge all alarms.

7.2.6 7.3

Battery Monitoring System Specifications The following table addresses the preferred battery monitoring system specification:
Input Power Operating Temperature Range Altitude Humidity Enclosure 120 Volts AC, 1 phase, 60 Hz 0 - 50C 0 - 5000 feet above sea level 10 95 % non-condensing Depending on installation and should be design according to NEMA 250 or IEC 60529 +/- 2 Degrees C

Temp. Measurement Accuracy Overall Battery Bank Voltage Individual cell voltage Current Measurement Accuracy Cell Impedance Measurement Accuracy

+/- 0.1 V +/- .01V +/- 1.0 % full scale +/- 10

7.4

System Software The system should be provided with up-to-date Windows based battery management software for interface between the BMS and the local or the remote computer. The software should manage all functions of the BMS and should provide analysis and trending of the battery data. The software should be able to auto-poll multiple monitoring systems on a programmed schedule. They system

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

should be password protected against any programming changes. The software should have different access privilege such as administrator, visitor, etc. 7.5 System Reporting The system should have the following reporting capabilities: Alarm condition instantaneous reporting. This automatic reporting by exception should be displayed at the monitor connected to the remote central computer and automatically dumped to a line printer connected to the remote central computer. Individual cell voltages over time (Data & Graph), graph should show optimum voltage line, maximum and minimum allowable limits. Individual cell impedance values over time (Data & Graph), the graph should show the maximum and minimum allowable limits. Total battery voltage over time (Data & Graph), graph should show optimum voltage line, maximum and minimum allowable limits. Battery & Room temperature over time (Data & Graph), this graph should also display the optimum temperature line. Discharge report Total battery voltage decay vs. time (Data & Graph). Discharge report Cell voltage decay vs. time (Data & Graph). Discharge report Cell dropout over time (Graph). Discharge interval summary report.

7.6

Drawings The vendor should supply the following drawings: Dimensional outline drawings of enclosures, cable entrance location details, and complete electrical wiring diagrams showing the interconnection of all components of the system. Installation drawings Equipment nameplate data Equipment specifications

7.7

Owner's Manual Each system should be provided with three (3) sets of owners manual(s) including the following information as a minimum:

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

7.8

Installation & commissioning instructions Operating instructions Service instructions with calibration & trouble shooting guide Spare parts list Factory test report

Testing 7.8.1 Factory Acceptance Tests: The BMS should be factory tested to demonstrate the functionality and performance required by this specification. The test report should be included in the Owners Manual. Site Acceptance Tests: Vendor should prepare site acceptance test procedures, which should be used to validate the functionality and performance required by this specification. Vendor should conduct the site acceptance tests and document the results. The Vendor should correct all deficiencies before final acceptance by the Buyer.

7.8.2

7.9

System Installation, Start-up, Commissioning & Training The BMS vendor should provide a field start-up engineer to supervise the system installation. After installation, the vendor field engineer should start up the system and perform all required site acceptance tests to demonstrate that the system meets the functionality and performance requirements of this specification. The field start-up engineer should also provide on-site training to the facility engineer and technicians.

Battery Monitoring System Measured Parameters The following information is obtained from IEEE 1491 & IEC 62060 regarding usual battery monitoring system obtained parameters, their description and corrective action. The typical parameters are usually monitored by the battery monitoring system are mentioned above in paragraph 7.2.1. IEEE 1491 indicates that battery monitoring system can be provided with additional parameters that depend on the battery monitoring system manufacturer such as: AC ripple current/voltage Specific Gravity Electrolyte level

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

8.1

Measured Parameters Indication The following will talk about each measure parameter meaning, indication and purpose of monitoring; 8.1.1 Float Voltage This is the voltage that is applied to the battery cell in the normal state by the battery charger in order to maintain its full charge condition. This value should be continuously monitored in order to indicate an out of range float voltage on any cell which will affect the battery life time. The proper float voltage is usually set by the battery manufacturer. Higher than normal float voltage for long time might result in accelerated grid corrosion, excessive gassing and increased water consumption, thermal runaway in VRLA batteries and premature end of life. Lower than normal float voltage will result in battery capacity loss, irreversible sulfation, accelerated grid corrosion and premature end of life. 8.1.2 Equalization Voltage Equalization voltage is a voltage level set by the battery manufacturer which is higher than the normal float voltage. Equalization voltage is usually applied in order to correct inequalities that happen in the voltage or specific gravity between batteries in the battery bank. Equalization voltage should be monitored in order to make sure that its value and duration is as recommended by the battery manufacturer. If equalization voltage is too high or too long, it will result in increased battery temp, excessive gassing, water consumption, grid corrosion and premature end of life. Low level equalization voltage might require longer time and too short equalization voltage might not achieve the desired results 8.1.3 Open Circuit Voltage This is the voltage at the battery terminal in case all charging sources and loads have been removed. This value is usually monitored in order to indicate if the open circuit voltage is within the manufacturer acceptable limits. The open circuit voltage can indicate cell state of charge or a shorted cell if the value is too low.

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

8.1.4

Battery Discharge Voltage Battery voltage can be monitored during battery discharging state. This value along with the discharge rate and time can be used to indicate battery health and also to predict battery performance.

8.1.5

Battery DC current Each individual cell current should be the same as the battery sting current if there is no ground fault present. Battery monitoring system can monitor the float current, discharge current, charge current and equalization current. All these values can be monitored and compared to the manufacturer data in order to indicate the state of health of a battery. The float current depends on the temperature, float voltage and battery condition. Big difference in the float current from the manufacturer recommendation may indicate problem in the battery system or the charging system. High level float current may indicate failing cells in the battery bank, high charge voltage, ground fault, contaminated electrolyte or high temperature. Absence of float current may indicate an open circuit or charging system failure. A rising trend of float current may indicate battery degradation and a start of thermal runaway in VRLA batteries. The magnitude of the discharge current compared with the battery capacity can give an indication of the run time. Each battery manufacturer should provide a table or chart of different discharge current values and the expected run-time of the battery. Also with a constant voltage, the charging current should come to a constant value when the battery becomes charged.

8.1.6

Cell Impedance Cell impedance is any ohmic value of resistance, conductance or impedance which is based on the relation between the voltage and the current in a stationary battery which is used as an indicator of a battery's state of health. Changes in the ohmic values in excess of a specified set value from the battery manufacturer at the same temperature should be considered significant and can indicate change in the battery health state. It is very important to establish a baseline of the internal cell ohmic value for future comparison. BMS can provide the trend of the cell internal impedance whether it is decreasing or increasing over time which might require close monitoring of the battery.
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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

In case there is a significant change in the cell internal impedance from the manufacturer recommendation or the established base historical value, more immediate testing such as a load test should be conducted in order to indicate the battery state of health. It should be noted that if cell ohmic value is still within allowable limit, this does not guarantee that the battery is in a healthy state. 8.1.7 Interconnection Resistance This is the resistance of the intercell connection measured between the battery connected posts which include both the resistances of the connection and the bolted connection. The typical value of the cell interconnection resistance is from 10~100 depending on the size of the battery. Corrective action should be taken if the value changes more than 20% from established baseline. 8.1.8 Battery Cell Temperature It is common to measure one pilot cell temperature in a battery bank and more measuring points are ok. Difference between ambient temperature and battery temperature should be monitored and always kept below manufacture recommendation. Increase in a battery cell temperature than ambient temperature may indicate higher than normal charging voltage, high ripple current or potential thermal runaway in VRLA batteries. Keeping a record of the battery operating & ambient temperature may be used for warranty validation. 8.1.9 Ambient Temperature The ambient temperature is one of the most critical parameters that should be monitored. The ambient temperature affects both the battery capacity and the battery lifetime. The battery lifetime is normally specified at 20~25C. If the ambient temperature is increased by 10C, the battery lifetime is expected to decrease by 50%. High ambient temperature also affects the battery self discharge and the battery float current. Both battery self discharge and float current increase with increase temperature. Also, more water consumption is expected with higher temperature.

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

8.1.10 Ripple Voltage and Current The ripple voltage and current is the AC component that is available in the DC bus. It is usual to have higher AC ripple voltage and current in UPS system batteries than in the DC system batteries since the load is not sensitive to DC ripples in UPS applications. Higher than normal voltage ripple may cause high water consumption in vented batteries and thermal runaway in VRLA batteries. High ripple voltage may indicate problem in the battery charger that need to be fixed. Higher than normal ripple current may generate heat within the battery which might increase the battery operating temperature. 8.1.11 Specific Gravity Specific Gravity is the ratio of the density of electrolyte to the density of water at specific temperature. During the discharge operation, acid is consumed and water is produced. During the charge operation, water is consumed and acid is produced. Because sulfuric acid is much denser than water, specific gravity measurement may be used for checking the state-of-charge of a battery. 8.1.12 Electrolyte Level At all times, the level of the electrolyte should be between the minimum and the maximum mark on the battery jar which is specified by the battery manufacture. This is very important to prevent plates drying. The rate of water consumption can give indication of an overcharging in healthy new cell or the need to replace an old cell.
Revision Summary New Saudi Aramco Best Practice.

5 June 2006

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Document Responsibility: CSD/ESD/Power Systems Unit Issue Date: 5 June 2006 Next Update: 5 June 2011

SABP-P-002 Selection and Design of Battery Monitoring System

Attachment # 1 General System Diagram

Battery Monitoring System on-site cabinet

Measurements of Voltage, internal impedance, current, tempsetc are obtained at the local BMS cabinet

Cell 1

Cell 2

Communication line, an example is Ethernet telephone line, RS-232 or RS485

Cell 3

Cell N

Remote BMS Computer at Central Control Room where BMS software is installed and data is collected

Battery Bank

This is preferred option to connect the system to Plant DCS.

Plant DCS

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