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This document discusses battery safety requirements, hazards, and precautions for lead-acid and nickel-cadmium battery systems and their electrolytes. It outlines potential hazards from electrolytes, electric shock, and hydrogen gas, as well as precautions to reduce or eliminate these hazards. Building support systems for battery rooms are also addressed. The document provides guidance on battery and UPS system start-up and commissioning procedures and interpreting test results.
Originalbeschreibung:
Its Saudi Aramco standard for Commissioning of DC & UPS System
This document discusses battery safety requirements, hazards, and precautions for lead-acid and nickel-cadmium battery systems and their electrolytes. It outlines potential hazards from electrolytes, electric shock, and hydrogen gas, as well as precautions to reduce or eliminate these hazards. Building support systems for battery rooms are also addressed. The document provides guidance on battery and UPS system start-up and commissioning procedures and interpreting test results.
This document discusses battery safety requirements, hazards, and precautions for lead-acid and nickel-cadmium battery systems and their electrolytes. It outlines potential hazards from electrolytes, electric shock, and hydrogen gas, as well as precautions to reduce or eliminate these hazards. Building support systems for battery rooms are also addressed. The document provides guidance on battery and UPS system start-up and commissioning procedures and interpreting test results.
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi Aramco and is intended for the exclusive use of Saudi Aramcos employees. Any material contained in this document which is not already in the public domain may not be copied, reproduced, sold, given, or disclosed to third parties, or otherwise used in whole, or in part, without the written permission of the Vice President, Engineering Services, Saudi Aramco. Chapter : Electrical For additional information on this subject, contact File Reference: EEX21106 W.A. Roussel on 874-1320 Engineering Encyclopedia Saudi Aramco DeskTop Standards Directing the Start-Up and Commissioning of DC/UPS Systems Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards CONTENTS PAGES BATTERY SAFETY REQUIREMENTS: HAZARDS AND PRECAUTIONS ..................................................................................................... 1 Building Support Systems ........................................................................... 1 Electrolyte ................................................................................................... 2 Hazards Present................................................................................ 2 Precautions for Reducing or for Eliminating Hazards ..................... 3 Electric Shock.............................................................................................. 4 Hazards Present................................................................................ 4 Precautions for Reducing or for Eliminating Hazards ..................... 6 Hydrogen Gas.............................................................................................. 6 Hazards Present................................................................................ 7 Precautions for Reducing or for Eliminating Hazards ..................... 7 BATTERY SYSTEM START-UP AND COMMISSIONING............................... 8 Pre-Startup and Commissioning Checks/Verification................................. 8 Initial Electrolyte Filling.............................................................................. 9 Initial Charging Procedures....................................................................... 13 Lead-Antimony Batteries............................................................... 13 Lead-Calcium Batteries.................................................................. 16 Cell Voltage and Specific Gravity Measurements..................................... 17 Cell Voltage ................................................................................... 17 Specific Gravity ............................................................................. 21 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards UPS SYSTEM START-UP AND COMMISSIONING........................................ 29 Verifying Proper Electrical Connections................................................... 29 Verifying Initial System Set-Up ................................................................ 30 Initial Conditions ........................................................................... 30 System Setpoints............................................................................ 31 Calibration Checks......................................................................... 35 Switching Functions ...................................................................... 35 Simulation of Line Power Source Loss ..................................................... 36 INTERPRETING START-UP AND COMMISSIONING TEST RESULTS....... 38 Battery System Start-Up and Commissioning........................................... 38 Battery Charger Start-Up and Commissioning.......................................... 41 UPS System Start-Up and Commissioning ............................................... 42 WORK AID 1: PROCEDURES AND CRITERIA FROM SADP-P- 103, IEEE 446, AND ESTABLISHED ENGINEERING PRACTICES FOR INTERPRETING START-UP AND COMMISSIONING TEST RESULTS........................................ 44 Procedure and Acceptable Values for Interpreting Start-Up and Commissioning Data ................................................................................. 44 GLOSSARY ......................................................................................................... 58 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 1 BATTERY SAFETY REQUIREMENTS: HAZARDS AND PRECAUTIONS The Electrical Engineer must recognize the potential dangers and hazards that are associated with batteries and battery systems. Through knowledge of the potential hazards, the Electrical Engineer can adequately prepare the technicians to eliminate the source of a hazard or to minimize the effects of a hazard. Failure to recognize or consider the areas of potential hazards could result in equipment damage or in injury to personnel. The following topics that are pertinent to potential hazards are discussed in this section: Building Support Systems Electrolyte Electric Shock Hydrogen Gas Building Support Systems The hazards when working with secondary batteries are increased when building support systems are non-existent or are inoperable. One responsibility of the start-up engineer is to verify the existence of these systems and their functional operation prior to initiating start-up procedures on the battery and UPS systems. The building support systems and the verifications that are required for each system are as follows: For battery rooms that use pressurized air systems, verify that the monitoring system actuates the local alarm on a loss of room pressurization. For battery rooms that use air exhaust systems, verify that the area exhaust fan operates. Verify that the battery room/UPS room is air conditioned to 25 o C. If the battery room temperature is below 25 o C, cell capacity is reduced. If the battery room temperature is consistently higher than 29 o C, cell life is shortened . Verify that eyewash facilities (portable or permanent) are installed and operable. (Eyewash facilities are not required for sealed battery installations.) Verify that floor drains are functional. Verify that portable water facilities are available for cleanup and flushing of electrolyte spills. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 2 Verify that the following safety items and test equipment are installed or are available for immediate use: - Chemical worker's goggles. - Face shield. - Apron. - Acid/alkaline resistant gloves. - A supply of bicarbonate of soda to neutralize sulfuric acid. - A supply of citric acid to neutralize potassium hydroxide (nickel- cadmium battery rooms). - Cell lifting straps and strap spreaders. - Thermometer to measure electrolyte temperature. - Hydrometer with temperature correcting scale to measure electrolyte specific gravity. Electrolyte Because of the abundance of electrolyte in large storage batteries, and because of the frequency with which electrolyte is handled, electrolyte is one of the major hazards that is associated with batteries. The Electrical Engineer must be familiar with the hazards that are associated with electrolytes and with the precautions to be taken to minimize these hazards. Hazards Present Electrolyte presents a hazard to equipment and personnel because of the electrolyte's acidic and alkaline properties. If electrolyte is improperly handled, the electrolyte will cause damage to the battery and to the battery rack, or it will cause injury to personnel. The hazard for equipment occurs from electrolyte that is spilled or dropped onto the equipment. Electrolyte is most likely to be spilled on the battery or on adjacent equipment during the initial battery fill and during the periodic electrolyte testing. If the spilled electrolyte is not properly neutralized and removed, the following problems could occur: The affected equipment will corrode and deteriorate over time. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 3 The electrolyte will contaminate the battery casing and will cause battery grounds. In installations that use wood support channels, excessive electrolyte that is absorbed into the wood can result in cell discharge through the saturated wood. The electrolyte that is spilled on the battery connections could impair electrical current flow. Personal hazards from electrolyte occur as a result of direct contact with electrolyte. The electrolyte that is used in the battery, sulfuric acid (acidic), or potassium hydroxide (alkaline), can cause skin burns, eye injuries, and clothing damage. Direct contact with the electrolyte can occur while the battery is being initially filled, during the periodic electrolyte testing, or as a result of casual contact with spilled electrolyte. Electrolyte that is spilled on the floor also produces slippery conditions that could be hazardous to personnel. Precautions for Reducing or for Eliminating Hazards The Electrical Engineer must be aware of the precautions that should be taken to reduce or to eliminate the hazards that are associated with battery electrolytes. The majority of the hazards to personnel and equipment occur from handling of the electrolyte during the filling and/or testing process. The use of common sense and good housekeeping practices will reduce or eliminate most of the hazards. The following guidelines will minimize the potential hazards that battery electrolytes present: All spills from the battery equipment should be rinsed away, and the spill area should be neutralized. After neutralization of the spill area, a final rinse should be performed through use of potable water. A bicarbonate of soda solution (100 grams per liter of potable water) should be used to neutralize sulfuric acid. A citric acid solution (90 grams per liter of potable water) should be used to neutralize potassium hydroxide. When working with electrolyte, personnel are to wear protective clothing, which is provided as part of the battery room safety equipment. Extreme care should be used in the removal of a cell vent cap or an arc suppressor. In the unlikely event of cell pressurization, such a removal could result in the release of electrolyte. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 4 Only battery handling straps and strap spreaders that are approved by the manufacturer should be used to transport or to physically handle the battery cells. When hydrometer tests are performed, the electrolyte should be removed with care to avoid unnecessary splashes and spills. To avoid overfill and splashes, electrolyte should be added to battery cells through use of proper cell electrolyte filling equipment. Electric Shock All personnel who work on or near batteries must remember that the possibility of electric shock exists at all times. The following topics that are pertinent to electrical shock are discussed in this section: Hazards Present Precautions for Reducing or for Eliminating Hazards Hazards Present Charged batteries that are connected in large series strings have the ability to deliver high short circuit currents. Because the short circuit current capability of these cells (batteries) can reach many thousands of amperes, the exposed conductors of a charged battery should be treated with respect and caution. Severe burns can result if metallic objects (such as jewelry and hand tools) make contact between two opposing cell terminals. Electrical shock hazards always exist with any series string of batteries. The shock hazard that batteries present is best illustrated through application of Ohm's Law (E = IR). For example, the resistance of damp skin can be as low as 300_, and the amount of current flow that normally is considered lethal is 0.1A. As Ohm's Law shows, a 30V (300_ X 0.1A = 30V) series string of batteries could produce a lethal shock. Electric shock hazards normally are only associated with large, high voltage battery installations; however, even smaller batteries, such as those found in communications equipment, forklifts, and automobiles, can pose an electric shock hazard. The most common causes of electric shock from a battery are simultaneous contact of the positive and negative terminals (by shorting out the positive and negative terminals with an uninsulated tool) or contact of a cell terminal with the common system ground. In addition to the electrical shock hazard, shorting the positive and negative terminals can damage the battery. Electrical shock hazards also can exist when the battery casing or the battery rack is touched. This hazard can exist because of dirty battery casings and electrolyte spills. The electrolyte Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 5 spills and the dirt can cause a low resistance current path from the battery terminal to the battery casing. In this situation, a shock hazard will exist if contact is made between the battery case and system ground. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 6 Precautions for Reducing or for Eliminating Hazards To reduce or eliminate electrical shock hazards, all personnel who work on or near batteries must be fully aware of hazards that are associated with batteries and the affects of electrical shock. The precautions for the reduction or the elimination of hazards of electrical shock in a battery room are the same as the precautions for all electrical systems. Common sense should prevail in instances that concern electrical equipment maintenance. Also, the following guidelines should be observed: Electrical safety gloves should be worn for work with the battery cables and the battery connections. Electrical safety goggles should be worn to protect against possible flashburns that are caused by short circuits. Electrical safety mats should be used to cover all exposed electrical parts in the work vicinity. All metal articles such as watches, rings, necklaces, and belt buckles should be removed from the body and from the clothing. All tools should be insulated so that no more than three inches of exposed metal exists. All tools should be properly secured during maintenance and should not be left unattended on the tops of the battery cells. All electrolyte spills should be immediately cleaned up, neutralized, and washed down. In case of an emergency, maintenance personnel should be qualified to perform first aid and cardiopulmonary resuscitation (CPR). Hydrogen Gas The potential hazards that are presented by hydrogen gas are most prevalent during charge and discharge operations in the battery room. This section will cover the following topics that are pertinent to hydrogen gas: Hazards Present Precautions for Reducing or for Eliminating Hazards Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 7 Hazards Present The greatest hazard that is associated with hydrogen (H 2 ) gas is a gas explosion. Under normal operating conditions, hydrogen accumulation in the battery room is not substantial and is not a major concern; however, during a battery charge, the battery-charging current generates H 2 gas at a rate that can produce explosive hydrogen-air mixtures. Hydrogen concentrations become flammable when the concentration in air is between 4% and 79% of the total battery room air volume. The hydrogen-gas air mixture is considered explosive when the hydrogen that is in the air exceeds 4% by volume. This 4% quantity is the Lower Explosive Limit (LEL) value. A properly designed ventilation system will provide a sufficient number of air changes per hour to keep the hydrogen concentration below 2% of the total volume of the battery room. In addition to the release of hydrogen gas, some batteries may release small quantities of toxic gases, such as stibine and arsine. Stibine and arsine are formed when the metals antimony and arsenic come in contact with hydrogen during a battery overcharge condition. Antimony and arsenic are commonly used in lead-acid batteries to strengthen the plate material and to reduce plate corrosion. Although the conditions that produce these toxic gases are rare, the Electrical Engineer must be aware that these conditions do exist. Because these gases are not monitored, maintenance of proper ventilation of the battery room is imperative. Good engineering design practices indicate that the ventilation that is required to maintain hydrogen concentrations below the 20% LEL (approximately 1% hydrogen) also will keep stibine and arsine below their toxic limits; therefore, if the ventilation system is correctly sized to prevent a hydrogen explosion, the threat of toxic poisoning from stibine and arsine is also eliminated. Precautions for Reducing or for Eliminating Hazards Hydrogen fires and explosions can be prevented through adequate battery room ventilation and through minimization of ignition sources. Hydrogen buildup is prevented by a well ventilated battery room. Ignition sources (such as smoking, open flames, and maintenance functions) that are capable of producing an open arc must be eliminated. A defective battery charger can cause excess hydrogen levels. If the charger malfunctions, excessively high battery charge rate can result. These high charge rates can produce substantial volumes of hydrogen. Adequate, periodic maintenance testing of the battery charger will reduce the possibility of such an overcharge condition. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 8 BATTERY SYSTEM START-UP AND COMMISSIONING This section of the Module will discuss the following topics that are pertinent to battery system start-up and commissioning: Pre-Startup and Commissioning Checks/Verification Initial Electrolyte Filling Initial Charging Procedures Cell Voltage and Specific Gravity Measurements Pre-Startup and Commissioning Checks/Verification Before the actual battery start-up and commissioning can begin, the Electrical Engineer must inspect the battery equipment for proper installation, acceptable equipment conditions, and security of electrical connections. The following items are to be checked and/or verified: Verify that the battery frame is assembled in accordance with the manufacturer's recommendations and that the battery frame is securely anchored to the floor. Check for any nicks or chips in the battery rack acid-proof paint. Any chips or nicks must be covered with touch-up paint that is provided by the battery rack manufacturer. If nicks or chips are not touched-up, and if corrosive electrolyte is spilled on the rack, the electrolyte will attack the exposed steel. Such attacks eventually can result in a structural failure of the battery rack and a possible battery rack collapse. Verify that the cells rest on plastic or wood support channels. These channels electrically insulate the cell from the steel frame. Inspect cells for electrolyte leakage that can occur as a result of a cracked jar or a broken seal. All damaged cells must be replaced. Check the color change temperature sticker that is applied to the exterior of each cell to determine whether the cell temperature has exceeded 45 o C. If color changes are observed, the affected cells must be replaced. Verify that the flame arrestor or the explosion-resistant vent caps, which collect electrolyte spray and return it to the cell, are intact and are properly installed. Check each connection for the correct complement of fastening hardware. Any connections that do not comply with the manufacturer's installation instructions must be corrected. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 9 Apply the correct torque to each battery connection through use of a torque wrench. The torque values must be in accordance with the manufacturer's recommendations. Verify that all terminal connector bolts, nuts, and washers have been coated with an anti-oxidant. Use the manufacturer's test instructions to collect the field data that establishes the initial connection resistance values of each battery post connection. These baseline resistance values will be used as comparison data for future maintenance procedures. The Individual Cell Terminal Resistance Record is included in Work Aid 1. At the completion of the intercell connections, a voltmeter should be used to check the polarity of the series connections. The total voltage of the series string should read approximately twice the number of cells (e.g., 2 x 60 cells = 120 volts). If the voltage is too low, one or more cells may be improperly connected. The battery string should be immediately inspected, and the faulty connection should be corrected. Initial Electrolyte Filling Cells that are received from the manufacturer already may be filled with electrolyte, or they may be in a dry charge state. The size and the weight of the cell usually determines the method of shipment. If the received cells are filled with electrolyte, the technicians only need to verify the electrolyte level and to measure the specific gravity of the electrolyte prior to the application of the initial (freshening) charge. If the cells are shipped dry charged, the Electrical Engineer must direct the initial electrolyte filling process and ensure that the proper electrolyte is used. If the battery will not be placed in operation immediately after installation, the initial filling should be delayed because dry batteries can be stored for longer periods of time than can wet batteries. Before cells that are received in a dry-charged state are filled, a verification must be performed to ensure that the cells are sealed and that the moisture vent cap is in place. A missing or a broken vent cap could indicate that the cell is contaminated. Each cell is to be filled to the correct level prior to the application of the freshening charge. The cells are to be filled with the correct electrolyte as directed by the cell manufacturer. Lead-acid cells use an electrolyte that consists of sulfuric acid and demineralized water; nickel-cadmium cells use an electrolyte that consists of potassium hydroxide and demineralized water. Concentration levels are dictated by the cell manufacturer. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 10 The use of demineralized or deionized water is essential to the chemical reaction within the cell. Demineralized water is to be used in order to prevent the formation of foreign mineral deposits on the cell plates. Such deposits contaminate the cell and shorten the life of the cell. The demineralized water is to be tested to ensure that the impurity levels do not exceed the following specifications: The water must be free from suspended matter and must be colorless when viewed through a depth of 300 mm (12 in). The total solids in the water must not exceed 20 parts per million (ppm). The chloride level must not exceed 20 ppm. Concentration levels of the following impurities must not exceed the levels that are shown: - Iron 10 ppm - Copper 5 ppm - Manganese 0.1 ppm - Lead 2.5 ppm - Calcium 10 ppm - Magnesium 10 ppm - Zinc 2.5 ppm To support the required chemical reactions of a battery, the diluted solutions of sulfuric acid and demineralized water or potassium hydroxide and demineralized water must be accurately measured to produce the proper mix of electrolyte. The concentration of acid in the electrolyte is determined through measurement of the specific gravity. The specific gravity of an electrolyte is the measure of the density of the electrolyte as compared to the density of demineralized water. For example, the specific gravity of demineralized water is 1.000, and the specific gravity of sulfuric acid is 1.835. Sulfuric acid, therefore, is 1.835 times denser (heavier) than demineralized water. To obtain the proper electrolyte concentration, various amounts of demineralized water (specific gravity 1.000) and sulfuric acid (specific gravity 1.835) are mixed. Dependent on the percentage of demineralized water and acid that is used, the resultant specific gravity of the diluted sulfuric acid will be between 1.000 and 1.835. Figure 1 shows the specific gravity of an electrolyte for various amounts of demineralized water and sulfuric acid. The figure illustrates that the specific gravity is lower for a higher volume of water in the electrolyte. The figure also shows that specific gravity for a smaller amount of water is much higher. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 11 The same relationship is shown with the percentage curve. As the percentage of acid in the solution increases, the specific gravity of the solution also increases. The exact specific gravity that is required for a given cell will be specified by the manufacturer. The specific gravity for a lead-acid battery is usually controlled in the range of 1.215 and 1.250. Sulfuric Acid - Water Concentrations Figure 1 Extreme caution must be taken when the acid and demineralized water are mixed. The acid and demineralized water should be mixed before they are added to the battery cells to ensure proper mixing of the electrolyte. Proper mixing of the acid and demineralized water will minimize stratification of the acid that could damage the plates of the cell. The following guidelines should be followed when electrolyte is mixed: Personal protective equipment should be worn. Eyewash stations should be readily available. Extra water supplies should be available in case of an electrolyte spill. The acid and demineralized water should be mixed in a properly ventilated area. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 12 When electrolyte is prepared for lead-acid batteries, the sulfuric acid must be introduced into the water. WARNING: Reversal of the mixing technique (e.g., introduction of water into sulfuric acid will result in a violent reaction that causes acid and water to splash from the mixing container. The acid should be "flowed" at a very slow pace and in small increments to allow time for the release of heat that is produced during the mixing procedure, which reduces the possibility of splashing. For potassium hydroxide solutions, the potassium hydroxide flakes or pellets should be carefully and slowly added to the demineralized water. Due to the excessive amounts of heat that are produced while potassium hydroxide is being mixed, field mixing is not recommended. The use of premixed solutions is recommended. After the proper type of electrolyte has been selected and mixed, the electrolyte can be added to the cells. All of the electrolyte safety precautions should be followed while the cells are filled. Each cell should initially be filled to the lower fill line because the electrolyte level will vary with the electrolyte temperature. The cell should be allowed to set for several hours (as recommended by the manufacturer) after the initial filling to allow time for the plates to soak. The soak time allows the plates to absorb electrolyte and allows the temperature of the electrolyte to stabilize. After the soak time has elapsed, the temperature of the electrolyte should be checked. Because the expansion and contraction characteristics of the electrolyte largely depend on cell design and on electrolyte volume, the Electrical Engineer must refer to the manufacturer's specifications to ensure that the electrolyte is in the proper range. For example, a storage battery design may result in an electrolyte level charge of 1/8 of an inch for every one degree change in electrolyte temperature. Therefore, if the temperature of the electrolyte during the initial fill is 15 o C, and if the ambient temperature of the battery room is 20 o C, the electrolyte level would be expected to rise 5/8 of an inch. This level rise would equate to 1/8 of an inch for each one degree change in temperature. The electrolyte level should be adjusted so that the level is in the normal operational range when the electrolyte reaches normal operating temperature. The operational range is indicated on the cell with upper and lower fill lines. This operational range is provided to allow for the expansion and contraction of the electrolyte. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 13 Initial Charging Procedures Initial charges are performed on batteries that have been shipped wet or that have been filled in the field. Wet cells typically are shipped in a fully charged state; however, the cells may loose some of their charge during shipping, handling, and installation. The initial charging procedure (freshening charge) is performed to bring the cell up to its fully charged state. Wet cells that are not immediately placed in service are to be periodically monitored to verify the cell's state-of-charge. Measurement of the cell's state-of-charge is accomplished through measurement of the specific gravity. A freshening charge must be applied to batteries that experience a 25 point (0.025) decrease in specific gravity. Wet cells that are not placed in service by the installation date that is recommended by the battery manufacturer also will need to undergo a periodic freshening charge. Cell manufacturers recommend shelf storage durations. These shelf periods vary by the type of cell and the electrolyte status (e.g., wet or dry charged). Cells that are received wet or cells that are made wet in the field may be stored; however, all wet cells must receive periodic charges while they are in storage. Cells that are filled with electrolyte should not be stored for long periods in an uncharged condition. The uncharged period varies between cell types. Stored lead-antimony cells require a periodic charge every three months; stored lead-calcium cells require a freshening charge every six months. The initial charging procedures will vary dependent upon the type of battery cells. The initial charging procedures for the following types of batteries are discussed in this section: Lead-Antimony Batteries Lead-Calcium Batteries Lead-Antimony Batteries Lead-antimony batteries must receive an initial charge within three months of the date of shipment from the manufacturer. This initial charge is called a freshening charge, a boost charge, or a forming charge, and it is typically applied by the constant potential charge method. The constant potential charge method is performed through application of a constant voltage to the battery terminals for the period of time that is specified by the manufacturer. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 14 Figure 2 shows the voltage and the current characteristics of a cell during a constant potential charge. Graph (a) of Figure 2 shows the steady output of the battery charger for the duration of the charge. Graph (b) of Figure 2 shows the battery cell voltage and the battery charge current for the duration of the battery charge. As shown in graph (b) of Figure 2, the cell voltage quickly rises to the charger output voltage when the charge is started. The battery charging current drops close to zero as the charge progresses. The freshening charge should continue at the manufacturer's specified voltage, which usually is the equalize voltage, for the period of time that is specified by the manufacturer to ensure that the battery cells are placed in a fully charged condition. The value of voltage that is applied to the cells and the length of time that the voltage is applied varies from cell to cell and from manufacturer to manufacturer. Constant Potential Charge Figure 2 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 15 Figure 3 shows the typical initial charge volts per cell and the charging time periods for a lead-antimony battery that has a nominal specific gravity of 1.215. The initial charge volts per cell (VPC) value that should be used for the initial charge can be calculated through division of the total system voltage by the number of cells that are in series. The total system voltage is the maximum voltage that the connected equipment will tolerate or the maximum voltage output capability of the battery charger, whichever value is less. The calculated initial charge VPC then is applied by the charger for the specified period of time (minimum hours) that is shown in Figure 3. During the initial charge, a pilot cell should be monitored to ensure that the battery electrolyte temperature does not rise above 49 o C. If the pilot cell electrolyte temperature reaches 49 o C, the charge must be stopped, and the batteries should be allowed to cool on open circuit. The battery charge should not be restarted until the pilot cell electrolyte temperature has lowered below 32 o C. Initial Charge Volts Per Cell (VPC) Minimum Hours for Nominal Specific Gravity of 1.215 2.39 2.36 2.33 2.30 2.24 40 60 110 168 210 Typical Initial Charge Values for a Lead-Antimony Battery Figure 3 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 16 Lead-Calcium Batteries Lead-calcium cells must receive an initial charge within six months of the date of shipment from the manufacturer. The initial charge of the lead-calcium cell can be delayed longer than the lead-antimony cell because the lead-calcium cell has a lower self-discharge rate and, therefore, will maintain its charged state for a longer period of time. The initial charge for a lead-calcium battery should be performed through application of an initial charge volts per cell (VPC) that corresponds to the nominal specific gravity of the battery. The battery manufacturer normally specifies a minimum acceptable initial charge VPC and a nominal initial charge VPC. The initial charge can be performed at any voltage that is within the specified range, but the preferred initial charge VPC is the nominal initial charge VPC. The output capabilities of the battery charger or the maximum voltage that can be applied to the connected load may prevent performance of the initial charge at the nominal initial charge VPC. Figure 4 shows the initial charge VPC values that correspond to typical lead-calcium battery nominal specific gravities. The duration of the initial charge for a lead-calcium battery is not fixed. The charge is continued until the lowest individual cell voltage value ceases to rise. After the lowest individual cell voltage ceases to rise, the charge is maintained for an additional 24 hours. During the initial charge, the individual cell voltage values must be monitored to determine when the lowest individual cell voltage ceases to rise. Also, the temperature of the pilot cells must be monitored to ensure that the electrolyte temperature does not exceed the values that were previously stated for lead-antimony batteries. Nominal Specific Gravity Initial Charge VPC Minimum Acceptable Nominal 1.170 1.210 1.225 1.250 1.275 1.300 2.10 2.13 2.15 2.18 2.20 2.23 2.29 2.33 2.36 2.38 2.40 2.45 Initial Charge VPC Values for Lead-Calcium Batteries Figure 4 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 17 Cell Voltage and Specific Gravity Measurements Cell voltage and specific gravity measurements are performed on each cell to ensure that each cell operates at the optimum condition. Measurement of cell voltage and specific gravity will provide an evaluation of the static charge, which provides an indication of the cell electro/chemical condition and battery cell capacity. The following topics will be discussed in greater detail: Cell Voltage Specific Gravity Cell Voltage Cell voltage is the electrical potential that is measured between the positive and negative terminals. Cell voltage is measured during an open circuit (no load) condition. The recorded voltage will be a true indication of the cell's standard potential or theoretical voltage and, when plotted on an X-Y axis graph, can be used to predict remaining battery capacity. Theoretical voltage or standard potential is calculated from the electrode potentials (e.g., oxidation potential of the anode and reduction potential of the cathode). Theoretical cell voltage is a function of the anode and cathode materials, the composition of the electrolyte, and the electrolyte temperature. With the cell temperature at the normal value of 25 o C, and with the specific gravity in the normal operating range, the measured cell voltage at open circuit is a close approximation of the theoretical voltage. The open circuit voltage of a cell depends on the state of the static charge. Figure 5 shows a typical cell voltage curve. The curve is a plot of open-circuit voltage vs. percent of rated capacity. If the cell has not been charged or discharged within 24 hours, the curve is accurate to within 20%. If the cell has not been used for five days, the curve is accurate to within 5%. The measurement of the open-circuit voltage to determine the state of charge is based on the relationship between the electromotive force (open-circuit voltage) and the concentration of the electrolyte in the battery. Electrolyte concentration level is determined through measurement of the cell specific gravity. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 18 Open-Circuit Voltage vs. State of Charge Figure 5 Ideally, the voltage of a new battery cell on open-circuit will approach the theoretical standard potential. Over a period of time, the electrolyte in the battery can become contaminated, and the battery plates will corrode and deteriorate. As a result, the cell's voltage will drop. In some instances, the contamination can be corrected through application of one or more equalizing charges that are followed by deep discharged cycles. If the charge/discharge cycles are successful, the battery cell's voltage will rise and approach the voltage of a new cell. If the charge/discharge cycles have no affect, as determined by an ever decreasing cell voltage, the cell must be replaced. Individual cell voltage readings are obtained through connection of a voltmeter across the positive and negative terminals of the cell. This measurement can be obtained through use of a portable voltmeter or can be observed at a permanently installed individual cell voltage (ICV) meter panel. Panelmeters provide a convenient way to check the individual cell voltages; however, because panelmeters reflect voltage losses that result from the meter leads (interconnecting wires), mechanical connections, selector switch, and the meter, panelmeters do not provide the most accurate indication of cell voltage. If the cell voltage that is indicated at the panelmeter appears questionable, a calibrated portable voltmeter should be used to verify the voltage of the cell that is in question. Each battery has several individual cell voltage ratings. These ratings reflect the electrical condition of the cell or battery and represent the voltage condition from fully charged to discharged. The individual cell voltages of a battery will vary with the operating Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 19 environment, the state of the charge, and the type of cell composition. The following is a list of the individual cell voltage ratings for a typical lead-acid and nickel cadmium battery: Individual Cell Voltage Lead-Acid Nickel Cadmium Open-Circuit Voltage 2.1 1.29 Nominal Voltage 2.0 1.2 Working Voltage 2.0-1.8 1.25-1.10 End Voltage 1.75 1.10 The open-circuit voltage is the difference in potential between the terminals of the battery cell when the battery circuit is open or at a no-load condition. The open-circuit voltage is the voltage that is closest to the theoretical or standard potential of a battery cell. The nominal voltage of a battery cell is defined as the characteristic operating voltage or the rated voltage of the cell. The nominal voltage is the value that is used to determine the total voltage of the battery (number of battery cells multiplied by the nominal voltage). The working voltage is the voltage that is representative of the actual operating voltage of the cell under load. The end voltage is defined as a point along the discharge curve below which no usable energy can be drawn for the specified application. The battery cell is then considered completely discharged. Through close monitoring of a battery's individual cell voltage during operation and charging, the Electrical Engineer can determine the general condition of any cell in the battery. Figure 6 shows a typical cell voltage curve during a battery discharge and charge cycle. Figure 6 also plots individual cell voltage over time for a battery discharge (time 0 to time 1) and a battery charge (time 1 to time 2). Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 20 Typical Discharge/Charge Curve of a Lead-Acid Cell Figure 6 At time 0, the cell voltage is at the nominal value, 2.00 volts. As the battery discharges from time 0 to time 1, the cell voltage drops to its end voltage of approximately 1.75 volts. At time 1, a battery charge is started and the cell voltage quickly rises above the nominal voltage value. The cell voltage will continue to increase until the charge is complete (time 2). When the charge voltage is removed, the individual cell voltage will decrease to the nominal value. If an individual cell voltage fails to respond in a similar manner, the cell is probably defective and should be removed from the battery for further maintenance evaluation. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 21 Specific Gravity The specific gravity is a measure of the density of an electrolyte in comparison to the density of pure water. The specific gravity of the electrolyte will vary with the state of charge as a result of the chemical reactions that occur within the cell. This section will discuss specific gravity as it relates to a lead-acid cell. During battery discharge, the density or weight of the electrolyte will decrease because of the disassociation of the sulfuric acid molecules; therefore, with less sulfuric acid in the battery cells, the specific gravity of the electrolyte will decrease. During a battery charge, the sulfuric acid is recombined to increase the specific gravity. Figure 7 shows the specific gravity of a battery for a cell discharge and a cell charge. The specific gravity plot overlaps the cell voltage plot that was previously described in Figure 6. Although no values are shown for specific gravity, the graph shows the relationship of the specific gravity to the volts per cell during a discharge/charge cycle. From time 0 to time 1, a constant cell discharge rate will result in a linear decrease in the specific gravity. During the charge cycle from time 1 to time 2, the specific gravity will rise to the nominal value, but the rise is not linear. A rapid excursion of specific gravity occurs when the cell voltage (volts per cell) rises above 2.4 volts and cell gassing occurs. Cell gassing causes turbulent electrolyte mixing, which causes the rapid rise in specific gravity. The state of charge of the cell can be determined through use of the specific gravity plot and is considered to be the most reliable indicator of the cell's state of charge. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 22 Typical Voltage and Specific Gravity Characteristics of a Lead-Acid Cell Figure 7 The specific gravity of the electrolyte is measured with a hydrometer. The most common type of hydrometer is the syringe type, as shown in Figure 8, view A. The hydrometer consists of a sample holding glass tube, a rubber bulb, and a float. The float is specially designed and calibrated to read the specific gravity of a solution when it is immersed in the solution. The hydrometer float consists of a hollow glass tube with a calibrated scale axially imprinted along the stem of the tube. The tube is weighted at one end and is sealed at both ends. Because each hydrometer float is calibrated for a specific range of specific gravities, accurate measurements of specific gravity only can be obtained through use of the correct float. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 23 Typical Hydrometer Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 24 Figure 8 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 25 To measure the specific gravity of a battery cell, electrolyte is drawn into the hydrometer holding glass tube in a sufficient quantity to cause the float to enter into suspension. Once the float is in suspension, the scale of the float is read at the meniscus interface of the float and the electrolyte. Typical examples of hydrometer readings also are shown in Figure 8. The example in view (B) shows that the float has sunk low in the electrolyte; the example in view (C) shows that the float is at a higher level in the solution. The float height difference between the two examples is due to the difference in the specific gravities of the sample electrolytes. The specific gravity of the solution is directly read from the calibrated scale, as indicated by the meniscus of the solution. For example, the hydrometer in view (B) indicates a specific gravity of 1150, and the hydrometer in view (C) indicates a specific gravity of 1270. The specific gravity readings of 1150 and 1270 are equivalent to 1.150 and 1.270 respectively but commonly are referred to as eleven-fifty and twelve-seventy. The following guidelines must be followed to obtain an accurate specific gravity measurement through use of a typical hydrometer: The interior of the hydrometer glass sample tube and the surface of the float must be clean. Dirty floats cause incorrect measurements, and dirty sample tubes can obscure the float scale. To avoid these conditions, the hydrometer should be periodically inspected and, if necessary, cleaned with a mild soap solution. All washed components should be rinsed with demineralized water before the components are re-assembled. Before the electrolyte sample that is to be read is drawn into the hydrometer, the electrolyte should be drawn into the hydrometer and then discharged into the cell two to three times to obtain a representative sample. Sufficient electrolyte must be drawn into the hydrometer in order to cause the calibrated tube to float in the electrolyte. The float must not touch the top or the bottom of the sample tube and it must remain relatively free of the sample tube sides. Specific gravity readings should be obtained before water is added to the cell. If water has been added, the hydrometer readings should be delayed until completion of an equalizing charge or until the electrolyte has had an opportunity to mix for at least one hour. The meniscus/scale interface should be held at eye level in order to prevent reading the float scale in parallax. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 26 At the completion of the measurement, all of the electrolyte should be returned to the cell from which it was removed. Before the hydrometer is placed in storage, it should be flushed with demineralized water. Because the measured value of specific gravity changes as the temperature and the level of the electrolyte changes, the measured values must be corrected to obtain the actual values. Figure 9 illustrates the change in the measured value of specific gravity with a change in cell electrolyte temperature. Specific Gravity vs. Temperature Figure 9 As the temperature of the electrolyte increases, the following changes occur to the electrolyte: The density of the electrolyte decreases, as measured by the hydrometer. The volume of electrolyte increases (i.e., the level of electrolyte increases). Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 27 The ratio of the weight of acid to the weight of water for a specific volume decreases; therefore, the measured specific gravity decreases. Conversely, as the electrolyte temperature decreases, the measured specific gravity increases. Because the temperature only affects the value of specific gravity that is measured by the hydrometer and not the actual value of available acid, the measured value must be corrected. This compensation correction will adjust all specific gravity readings to a standard temperature (25 o C). Adjustment of the readings for the temperature will provide accurate specific gravity readings. These readings will then permit accurate comparisons between cells. The following guidelines are used to adjust the specific gravity readings to a standard temperature of 25 o C: Add one point (.001) to the specific gravity reading for every 1.67 o C that the electrolyte temperature is above the 25 o C standard. Subtract one point (.001) from the specific gravity reading for every 1.67 o C that the electrolyte temperature is below the 25 o C standard. A change in electrolyte level also will affect the measured value of specific gravity. This change is due to the change in concentration of the acid and the water in the electrolyte. Electrolyte levels can change for the following reasons: Evaporation Leakage Spillage of electrolyte during sampling Extreme temperature changes Addition of water to the cell The actual change in specific gravity that occurs as a result of electrolyte level changes will vary with the size of the battery and the electrolyte concentrations. In some installations, a change in level can have a negligible effect on the specific gravity as long as the electrolyte remains in the normal range. In other installations, the change in electrolyte level can be significant. The manufacturer's technical literature must be consulted to obtain the electrolyte level correction factor for each particular battery. The expected specific gravity readings of a cell will depend on the type of cell, the type of electrolyte, and the state of charge of the cell. Typical specific gravity readings for a lead- acid and a nickel-cadmium cell are provided in Figure 10. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 28 The readings reflect various states of charge that range from a fully discharged battery to a fully charged battery. The values that are provided in Figure 10 are representative of the values that would be measured during a battery discharge at a constant discharge rate. A battery that is being charged or that is being heavily discharged will not produce accurate specific gravity readings. As previously shown in Figure 7, the specific gravity will linearly decrease during a battery discharge; however, during a charge, the specific gravity rises in a non-linear fashion. Typical Specific Gravity Readings Figure 10 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 29 UPS SYSTEM START-UP AND COMMISSIONING The start-up and commissioning procedure of a UPS system consists of a series of system checks and tests that are performed in coordination with the manufacturer. The testing methods and the procedural steps to perform the start-up and commissioning will be provided by the equipment manufacturer and will be approved by Saudi Aramco. The resultant data are to be recorded on the Start-Up and Commissioning Test Results Data Sheet. This section will provide information on the following topics that are pertinent to UPS system start-up and commissioning: Verifying Proper Electrical Connections Verifying Initial System Set-Up Simulation of Line Power Source Loss Verifying Proper Electrical Connections The purposes for verifying proper electrical connections during start-up and commissioning of a UPS system are the following: to confirm that no loose connections exist that could arc and present a hazard to personnel; and to verify that the interconnecting wiring is correct (to avoid possible damage to the system equipment). The electrical equipment of a UPS system should not be energized until all electrical connections have been visually inspected. The visual inspection should include but should not be limited to the following: Verify that all electrical components are installed in accordance with the design documents. Verify that all field wiring has been installed in accordance with the project electrical drawings. Check all electrical terminations, field connections, and vendor equipment for tightness. Check electrical conductor insulation for any breaks, voids, or signs of materials stress. Verify that electrical conductors are free of any sharp edges or moving parts that will damage the insulation. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 30 Verifying Initial System Set-Up The initial system set-up will verify all of the operational functions of the UPS system. The system set-up will include the following areas: Initial Conditions System Setpoints Calibration Checks Switching Functions Initial Conditions The Electrical Engineer must verify that all the UPS system manufacturer's technical manuals have been received and that these manuals apply to the specific installation. Many of the manufacturer's technical manuals are equipment specific, and a non-applicable manual can create major problems. The Electrical Engineer must verify that all overcurrent protection fuses have been installed and are of the correct value. If the fuses are undersized, they can unnecessarily trip. If the fuses are oversized, they may permit excessive current flows that can result in possible damage to the equipment. A check of the available incoming power sources also is an initial condition requirement. These incoming power sources consist of a preferred ac power source that normally connects to the inverter circuit and an alternate ac power source that connects to the static switch and the manual bypass switch. Some installations may further segregate the power through use of a third incoming ac power source that would connect to the manual bypass switch. In this case, the alternate ac power source would supply only the static switch. The Electrical Engineer must verify that the inverter and the battery charger enclosure ventilation fans properly operate. An inoperable fan or a restricted air flow can produce excessive temperature in the interior of the enclosure. These excessive temperatures can cause operational failures and premature electrical component failures. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 31 System Setpoints System setpoints consist of two types: alarm and control. The purpose for verifying alarm setpoints during UPS system start-up and commissioning is to check the alarm points of the monitored parameters. The alarm points monitor selects system parameters and will "alarm" when a parameter is reached or exceeded. Operating in the extremes of these maximum and minimum parameters is conducive to component/system failure. The control setpoints are used to establish the nominal UPS system operating conditions. An initial check of these control setpoints is necessary to establish functionality and a point of control, as well as to establish baseline conditions. Alarm Setpoints- Each UPS system is provided with a number of alarm points. The parameters that are to be monitored are dependent on the installation and design requirements. Saudi Aramco design specifications and manufacturer suggestions will determine which of the system parameters will be monitored by an alarm circuit. Procedural steps for testing each alarm point are provided in the manufacturer's technical manual. The following is a list of the alarms that are associated with a typical UPS system: dc Input Voltage High Alarm dc Input Voltage Low Alarm Alternate Voltage/Sync Source Not Available Alarm Static Switch Position Indication Alarm Output Failure Alarm Enclosure Overtemperature Alarm The dc Input Voltage High Alarm indicates the point at which the dc input to the inverter has reached or exceeded a specified maximum operating condition. The alarm setpoint is adjustable and should be set at a value of +5.0% of the nominal dc input voltage. The dc Input Voltage Low Alarm indicates the point at which the dc input to the inverter has reached or exceeded a specified minimum operating condition. The alarm setpoint is adjustable and should be set at a value of -5.0% of the nominal dc input voltage. The Alternate Voltage/Sync Source Not Available alarm will actuate when the alternate power source voltage is not available at the static switch. If the alternate power source is not available, and if an inverter failure occurs, power to the critical load will be lost. The alternate power source is considered "not available" when the voltage deviates from the nominal system voltage by +/- 10% or when the frequency deviates from the nominal system frequency by +/- 5%. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 32 The Static Switch Position Indicator alarm will energize when the static switch transfers from the inverter to the alternate power source. This alarm, as a result of the static switch transfer, indirectly indicates that the inverter has failed; therefore, the subject alarm should be accompanied by an Inverter Output Failure Alarm. The Inverter Output Failure Alarm will warn of a loss of inverter output power. This alarm occurs if the output voltage deviates outside of the range of +/- 10% or if the frequency deviates more than +/- 5.0% of the nominal 60 Hz value. The Enclosure Overtemperature alarm warns that the inverter equipment is operating at above the normal temperature. Overheated inverter electrical components can result in abnormal output voltage and frequency conditions. Continuous overheating of the electrical components may result in a premature equipment failure. Control Setpoints- A UPS system is to provide pure, fully conditioned power to the critical loads. This power is to be controlled and regulated within specific conditions. Setpoint adjustments are provided to achieve this required regulation and control. The regulation and control adjustments are as follows: Output Voltage Output Frequency Phase Relationship Waveform Purity and Harmonic Distortion Level Static Switch Transfer/Re-Transfer Voltage Monitor Static Switch Transfer/Re-Transfer Frequency Monitor Battery Isolation Circuit breaker Shunt Trip Output Voltage- The general requirements of a UPS system are that the voltage output from the static inverter must be at the design nominal voltage +/- 10%, at a frequency of 60 Hz +/- 5.0%, and in-phase with the ac source voltage. The input to the static inverter can be from the stationary battery or from the output of the battery charger, and the input must be verified before adjustment of the static inverter output voltage. The purpose for verifying the output voltage adjustment during UPS system start-up and commissioning is to ascertain that the inverter is producing an output voltage that is within acceptable tolerance. Typically, the battery output and the battery charger output voltage should be in the range of +/- 10% of the dc nominal voltage. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 33 If the battery output voltage is not within specification, the individual cell voltages and the specific gravities should be checked, and the battery should be charged. If the battery output voltage does not return to the normal range, additional battery troubleshooting should be performed. If the battery charger output voltage is within the proper range, the static inverter voltage can be adjusted on the inverter's internal control module. If the battery charger output voltage is not within the range of +/- 1.0% of nominal value, the battery charger output voltage should be adjusted. The static inverter's output voltage is adjusted through a variance in the delay time or firing angle of the SCRs. The output voltage should be adjusted when no load is applied to the static inverter. This adjustment procedure is accomplished through installation of a portable voltmeter on the inverter output. While the portable test meter is being monitored, the output voltage control that is located on the inverter electronic control board is adjusted to set the output voltage to the nominal value. After all of the voltage adjustments have been made, the output voltage should be rechecked with the static inverter connected to the critical ac loads. Under electrical load, the output voltage again should be monitored for voltage level abnormal transients and waveform purity. Adjustment to the firing angle of the SCRs affects only the magnitude of the voltage and does not directly affect the frequency or the phase angle of the output voltage. Output Frequency - After the input voltage has been adjusted, the frequency of the output voltage should be checked. If the output from the static inverter is not at 60 Hz, the transfer from the preferred source to the alternate will not be a smooth transfer. The output frequency from the static inverter should be monitored with the ac source reference deenergized or disconnected. Deenergization of the ac source voltage will ensure that the static inverter is not synchronized with an external source that may prevent adjustment of the static inverter output frequency. A convenient method to monitor the static inverter output is with an oscilloscope. The oscilloscope should indicate a 16.7 millisecond period for one complete cycle. If the frequency is not at 60 Hz, the frequency can be adjusted on the static inverter's oscillator board. Phase Relationship - When the static inverter's output voltage and frequency are within specification, the phase relation between the inverter output and the ac line should be checked. This relationship easily can be seen on a dual trace oscilloscope. The phase relationship between the two sources should be zero and can be adjusted on the synchronizing board of the static inverter. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 34 Static Switch Transfer/Re-Transfer Voltage Monitor - The electronic circuit of the static switch monitors the inverter output voltage. If the output voltage fluctuates outside the range of +/- 10% of the nominal inverter output voltage, the static switch will immediately transfer (less than 4.2 milliseconds) to the alternate source. The static switch will remain in the diverted or alternate position until the following conditions are satisfied: Inverter output voltage returns to within +/- 2.0% of nominal output voltage. Inverter and alternate source are phase-synchronized. The above two conditions have been maintained for a duration of at least 30 seconds before re-transfer is permitted. At this time, the static switch will transfer back to the inverter (preferred) source. Static Switch Transfer/Re-Transfer Frequency Monitor - The electronic circuit of the static switch also monitors the inverter output frequency. If the output frequency fluctuates outside the range of 60 Hz (+/- 5.0%), the static switch will immediately transfer (less than 4.2 milliseconds) to the alternate source. The static switch will remain in the diverted or alternate position until the following conditions are satisfied: Inverter output frequency returns to 60 Hz (+/- 2.0%). The above frequency value has been maintained for a duration of at least 30 seconds before re-transfer is permitted. Battery Isolation Circuit Breaker Shunt Trip - A two pole circuit breaker is installed in the dc circuit ahead of the inverter. This breaker is designed to "trip" in the event of a low dc voltage. A shunt trip circuit in the breaker monitors the dc voltage. If the dc voltage to the inverter exceeds the -10% range of the nominal dc voltage, the shunt trip monitoring circuit will energize to trip the breaker in order to protect the battery from discharging below the final battery voltage. (For the final battery voltage value, the equipment manufacturer's technical manual is to be consulted.) Waveform Purity and Harmonic Distortion Level - The waveform of the static inverter output should be monitored on start-up to ensure that the inverter can produce an output that is comparable to the manufacturer's specifications. Although absolute limits on the waveform distortion do not exist, the measured waveform should model the waveforms that are supplied by the manufacturer. The inverter output should be checked with a spectrum analyzer for harmonic distortion. Harmonic distortion that is greater than 4% can cause problems with electronic equipment. If harmonic distortion exceeds the maximum allowable level of 4%, the equipment manufacturer should be contacted. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 35 Calibration Checks Part of the set-up and commissioning of the UPS system, in addition to checking and establishing alarm and control setpoints, is to verify that the panelmeters are accurate. The panelmeters provide a convenient means to monitor the important system parameters. The panelmeters provide a continuous indication of the monitored parameters. The readings obtained from panelmeters are to be within +/- 2.0% of the readings that are obtained with a calibrated test instrument. Switching Functions The majority of UPS systems have a manual bypass switch. The manual bypass switch is used during the performance of maintenance and testing functions. Three-phase (3_) systems also employ panelmeter selector switches. This section provides information on the following topics that are pertinent to switching functions: Manual Bypass Switch Panelmeter Selector Switches Manual Bypass Switch - The manual bypass switch provides a method to connect the critical ac loads directly to a reliable source of power with no downtime of the loads. The inverter then can be isolated for safe inspection, testing, and maintenance. Two- way bypass switches perform the following functions: To shunt the power potential around the inverter without interrupting the inverter output power. Flow of current divides between the bypass switch contacts and the inverter to ensure that not even a momentary interruption of power to the critical loads occurs in the event of an inverter failure. To allow the inverter to be electrically tested and adjusted without interrupting or affecting power to the critical load. The inverter output is disconnected from the critical load, but the inverter is still energized from the normal and emergency sources and can be electrically tested without affecting the critical load. To electrically isolate the inverter from the preferred and alternate source of power and from the critical load in order to permit inspections and maintenance of the inverter. In this position, the inverter is completely isolated while the critical load continues to be fed through the bypass contact. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 36 Panelmeter Selector Switches (3_ Systems) - Selector switches, when used in conjunction with a panelmeter, allow individual three-phase parameters to be monitored with one meter. In systems that do not require simultaneous continuous monitoring of the parameters, the use of a single meter and a selector switch is more economical. Selector switches are provided to monitor the following parameters: Voltage - Switch positions: A-B, B-C, A-C, L-N Frequency - Switch Positions: A_, B_, C_, L-N Amperage - Switch Positions: A_, B_, C_ Simulation of Line Power Source Loss The purpose of simulating a line power source loss is to verify that a UPS system will properly operate under the designed conditions to provide an uninterrupted, bumpless transfer to the alternate source of power. Two conditions must be observed to ensure the proper operation of the UPS system: the transfer of power from the preferred power source to the alternate power source and the transfer of power from the alternate source to the preferred source. The following sequence of events should be observed during the performance of the simulated line power source loss test: When the UPS system is in automatic, and when the preferred source of power (output of the inverter for a reverse transfer scheme) is available, the inverter output supplies power to the critical load. In this situation, the input to the inverter can be the ac preferred source via the battery charger or the stationary battery. If any of the following conditions occur, a transfer signal will be generated and a transfer will occur: - The inverter output voltage goes outside of the normal range (i.e., _ 10% of the nominal voltage). - The inverter output frequency goes outside of the normal range (i.e., _5% of the nominal frequency). - An external transfer signal, such as the inverter in the current limit mode of operation, is present. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 37 A line power source loss can be simulated through performance of one of the following actions: - Open the dc input breaker to the inverter. - Open the ac input breaker to the battery charger and open the battery output breaker. - Open the battery output breaker and, through use of a variable ac input source, vary the ac voltage outside of the normal range. If a transfer inhibit signal is not present, the transfer to the alternate source will occur. If a transfer inhibit signal is present, the transfer will be blocked and the corresponding alarm will occur. The following are examples of conditions that will result in a transfer inhibit signal and a blocked transfer: - The alternate power source voltage is outside of the normal range (i.e., _10% of the nominal voltage). - The alternate power source frequency is outside of the normal range (i.e., 60 Hz _5% of the nominal frequency). - An external transfer inhibit signal, such as a sync disconnect signal, is present. The ac alternate source will continue to supply power to the critical loads until the external transfer signal is removed from the preferred source sensing circuit and the following conditions are met: - The inverter output voltage returns to _2% of the nominal voltage and remains at this value for at least 30 seconds. - The inverter output frequency returns to _2% of the nominal frequency and remains at this value for at least 30 seconds. When the above conditions have been met, the critical load will be transferred to the inverter output, which is the preferred source of power. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 38 INTERPRETING START-UP AND COMMISSIONING TEST RESULTS A major function of the Electrical Engineer during the course of a battery and UPS installation is to monitor and to direct the actions of the maintenance personnel. After the installation, and prior to placement of the equipment in service, the Electrical Engineer has an equally important role to monitor and to analyze the results of the installation tests and inspections. Through an analysis of the results of the tests and inspections, the Electrical Engineer can determine whether the battery and UPS system installation is acceptable or can determine what must be done to make the installation acceptable. This section will cover the following topics that are pertinent to interpretation of start-up and commissioning test results: Battery System Start-Up and Commissioning Battery Charging Start-Up and Commissioning UPS System Start-Up and Commissioning Battery System Start-Up and Commissioning The determination of the acceptability of the battery system relies on the following items: The completeness of the battery tests and inspections. The accuracy of the battery system test data. The correct interpretation of the battery system test data. The completeness of the tests and inspections is primarily fixed by the data sheets that are provided to the Engineer from Saudi Aramco and the battery manufacturer. Although the Electrical Engineer may specify additional tests for the battery, the start-up and commissioning tests that are presented in this Module normally are more than adequate to provide the information that is needed to commission a battery. The accuracy of the battery test data depends on the qualifications and experience of the maintenance staff and on the application of the test equipment. Interpretation of this data must be performed by an Electrical Engineer who is familiar with normal and abnormal conditions that pertain to battery systems. To begin the interpretation of the results of battery system start-up and commissioning, the Electrical Engineer will require the following data sheets: DC/UPS System Start-up and Commissioning Test Results Data Sheet Individual Cell Terminal Resistance Test Record Battery Test Record Battery Acceptance Test Data Sheet Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 39 These data sheets are provided in Work Aid 1. The DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Figure 16 of Work Aid 1) is divided into four sections: Pre-Commissioning Checks Battery System Checks Battery Charger Setpoints and Calibration Checks UPS System Checks and Setpoints The Pre-Commissioning Checks section of the data sheet applies to the Battery Charger and UPS system as well as the battery system. The Battery Charger data and the UPS system data will be discussed later in this Module. The Pre-Commissioning Checks section and the Battery System Checks section of the DC/UPS System Start-up and Commissioning Test Results Data Sheet should be checked to ensure that data have been recorded in all of the blanks and that the data sheet has been properly signed and dated. The Remarks section should be checked for any noted abnormalities. The Electrical Engineer also should verify that the Individual Cell Terminal Resistance Test Record, the Battery Test Record, and the Battery Acceptance Test Data Sheet have been properly completed and are included in the review package. Before the battery system equipment data are analyzed, the Electrical Engineer must verify the satisfactory completion of the Pre-Commissioning Checks. Any abnormalities or operational conditions that are outside of the nominal operational range for the battery can affect the outcome of the remainder of the data that were collected. If the Electrical Engineer determines that one or more of the pre-commissioning checks is unsatisfactory, he must determine whether this unsatisfactory condition impacts the validity of the remainder of the results. If the Electrical Engineer determines that the validity of the remainder of the results is affected, he should ensure that the unsatisfactory condition is corrected and that the affected start-up and commissioning tests are performed again. The Battery System Checks section of the DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Figure 16 of Work Aid 1) consists of seven items that must be verified. Verification of each item is to be performed in accordance with the procedure and the acceptance criteria that are located in Work Aid 1. The first test results to be reviewed are the Individual Cell Terminal Resistance Test Record (Figure 17 of Work Aid 1). If the terminal resistances are high, they will reduce the output voltage of the battery. Resistance values that do not meet the acceptance criteria that are located in Work Aid 1 must be corrected before the startup and commissioning evaluation is continued. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 40 After verification of satisfactory cell terminal resistances, the Electrical Engineer should review the Battery Test Record results. The following data on the Battery Test Record (Figure 18 of Work Aid 1) should be analyzed for each cell: Individual cell voltage Specific gravity (temperature corrected to 25oC) The individual cell voltage should be within the range that is specified by the acceptance criteria that are located in Work Aid 1. The individual cell voltages also should be checked in comparison to the other cells of the battery to ensure that the maximum deviation between the cell voltages does not exceed the values that are specified in Work Aid 1. Any deviation that is outside of these normal cell voltages indicates a problem with the battery cell and will affect the overall efficiency of the battery. The individual cell voltages can be off specification for a number of reasons. The following is a partial list of these reasons: An improper charge on the battery cell. A poor intercell connection. An improper reading by the maintenance staff. A defective cell. If the individual cell voltage is off specification, the individual cell voltage should be taken a second time to determine whether the initial reading was accurate. If the reading was accurate, the torque and the resistance of the affected intercell connections should be rechecked, and the battery should be recharged with the proper charging procedure. In any case, the manufacturer's technical literature should be consulted for additional troubleshooting steps and for additional corrective actions. The temperature-corrected specific gravity for each cell should be within the range that is specified by the acceptance criteria that are located in Work Aid 1. The specific gravity also should be checked in comparison to the other cells of the battery to ensure that the maximum deviation between the specific gravities does not exceed the values that are specified in Work Aid 1. Any deviation that is outside of these normal specific gravity readings indicates a problem with the battery cell and will affect the overall efficiency of the battery. The specific gravity readings can be off specification for a number of reasons. The following is a partial list of the reasons: An improper charge on the battery cell. An improper reading by the maintenance staff. An improper temperature correction was applied. An incorrect hydrometer was used. The readings were taken after the battery was watered. The cell is defective. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 41 If the specific gravity is off specification, the specific gravity should be taken a second time to determine whether the initial reading was accurate. If the reading was accurate, the temperature correction calculation should be rechecked; the equipment that was used to make the measurement should be checked to ensure that it is the correct equipment; and, if required, the battery should be recharged with the proper charging procedure. In any case, the manufacturer's technical literature should be consulted for additional troubleshooting steps and for additional corrective actions. Individual cells that do not meet the acceptance criteria should be replaced, and the battery should be recharged in accordance with the manufacturer's recommended charging procedures. After completion of the verification of the Battery Test Results, the Electrical Engineer should review the Battery Acceptance Test Data Sheet (Figure 19 of Work Aid 1). The battery acceptance test results should indicate that the battery can sustain a specific discharge rate for a specified time duration in accordance with the manufacturer's rating. The discharge rate should be a constant current load that is equal to the manufacturer's rating of the battery for the selected test length. The selected test length should be the time that the battery is required to supply the critical loads. Battery Charger Start-Up and Commissioning The ability to determine the acceptability of a battery charger relies on the following: The completeness of the battery charger tests and inspections. The accuracy of the battery charger test data. The correct interpretation of the battery charger test data. The completeness of the tests and inspections is primarily fixed by the data sheets that are provided to the Engineer from Saudi Aramco and the battery charger manufacturer. Although the Electrical Engineer may specify additional tests for the battery charger, the start-up and commissioning tests that are presented in this Module normally are more than adequate to provide the information that is needed to commission a battery charger. The accuracy of the battery charger test data is dependent on the qualifications and experience of the maintenance staff and on the application of the test equipment. Interpretation of this data must be performed by an Electrical Engineer who is familiar with normal and abnormal conditions that pertain to battery chargers. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 42 At the start of the verification of the start-up and commissioning test results, the Electrical Engineer must check to see that data are recorded in all of the line items that are shown in the battery charger section of the DC/UPS System Start-Up and Commissioning Test Results Data Sheet. The Remarks section also should be checked for any abnormalities. Abnormalities or operational conditions that are outside the nominal operational range for the battery charger can affect the validity of the collected data. The Electrical Engineer must determine whether any abnormal conditions exist. If such conditions do exist, the Electrical Engineer must determine whether the condition has an effect on the validity of the collected data. If the Electrical Engineer determines that an abnormal condition does affect the validity of the collected data, the Electrical Engineer should have the abnormal condition corrected and should have the affected tests performed again before the start-up and commissioning evaluation is continued. The data that are recorded in the Battery Charger Setpoints and Calibration Checks section should be interpreted through use of steps 3a through 3k of the procedure and acceptance criteria that are located in Work Aid 1. UPS System Start-Up and Commissioning The ability to determine the acceptability of a UPS system relies on the following: The completeness of the UPS system tests and inspections. The accuracy of the UPS system test data. The correct interpretation of the UPS system test data. The completeness of the tests and inspections is primarily fixed by the data sheets that are provided to the Engineer from Saudi Aramco and the UPS system manufacturer. Although the Electrical Engineer may specify additional tests for the UPS system, the start-up and commissioning tests that are presented in this Module normally are more than adequate to provide the information that is needed to commission a UPS system. The accuracy of the UPS system test data are dependent on the qualifications and experience of the maintenance staff and the application of the test equipment. Interpretation of this data must be performed by an Electrical Engineer who is familiar with the normal and the abnormal conditions that pertain to UPS systems. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 43 At the start of the verification of the start-up and commissioning test results, the Electrical Engineer must check to see that data are recorded in all of the line items that are shown in the UPS system section of the DC/UPS System Start-Up and Commissioning Test Results Data Sheet. The Remarks section also should be checked for any abnormalities. Abnormalities or operational conditions that are outside of the nominal operational range for the UPS system can affect the validity of the collected data. The Electrical Engineer must determine whether any abnormal conditions exist. If such conditions do exist, the Electrical Engineer must determine whether the condition has an effect on the validity of the collected data. If the Electrical Engineer determines that an abnormal condition does effect the validity of the collected data, the Engineer should have the abnormal condition corrected and should have the affected tests performed again before the start-up and commissioning evaluation is continued. The data that are recorded in the UPS System Checks and Setpoints sections should be interpreted through use of steps 4g through 4x of the procedure and the acceptance criteria that are located in Work Aid 1. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 44 WORK AID 1: PROCEDURES AND CRITERIA FROM SADP-P-103, IEEE 446, AND ESTABLISHED ENGINEERING PRACTICES FOR INTERPRETING START-UP AND COMMISSIONING TEST RESULTS Procedure and Acceptable Values for Interpreting Start-Up and Commissioning Data 1. Verify that all of the pre-commissioning checks that are listed in Figure 16, DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Page 1), have been satisfactorily completed. Satisfactory completion of the pre-commissioning checks is indicated by an "X" in the Yes column. 2. Verify that the start-up and commissioning results of the Battery System checks that are listed on Figure 16, DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Page 1), are satisfactory. 2a. Verify that all of the required safety equipment is present and operable. The presence and operation of the required safety equipment is indicated by an "X" in the Yes column. 2b. Verify that the test equipment and special tools are available. The availability of the test equipment and special tools is indicated by an "X" in the Yes column. 2c. Verify that the battery rack is assembled and correctly installed. The assembly and correct installation of the battery rack is indicated by an "X" in the Yes column. 2d. Verify that the battery cells and support equipment are correctly installed. Correct installation of the battery cells and support equipment is indicated by an "X" in the Yes column. 2e. Verify that the initial battery cell terminal resistances are satisfactory through comparison of the resistance values that are recorded on Figure 17, Individual Cell Terminal Resistance Test Record, with the acceptable values for battery cell terminal resistance that are listed below: Battery Cell Terminal Resistances The acceptable value for battery cell terminal resistance is that no cell terminal should have a resistance that exceeds 10% or 5__, whichever is greater over the average of all of the cell terminal resistances. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 45 2f. Verify that the battery test results are satisfactory through comparison of the data that are recorded on Figure 18, Battery Test Record, with the acceptable values for the battery test that are listed below: Battery Cell Temperatures The acceptable value for battery cell temperature is that no cell should deviate more than 3 o C (5 o F) from any other cell. Cell Voltage The acceptable value for battery cell voltage is that no cell voltage should have a value that is lower than 2.10 volts (1.215 specific gravity) for lead-acid cells and 1.29 volts (1.300 specific gravity) for nickel-cadmium cells. Cell Specific Gravity The acceptable value for battery cell specific gravity is that no cell specific gravity should have a value, after corrected for temperature and electrolyte level, of more than 10 points (0.010) below the average of all cells. Battery Compartment Condition Satisfactory condition of the battery compartment is indicated by an "X" in the space that is adjacent to the "clean" and the "dry" selections. Connections and Terminal Conditions Satisfactory condition of connections and terminal condition is indicated by an "X" in the space that is adjacent to the "Satisfactory" and the "Tight" selections. Cell Case Condition Satisfactory condition of each cell case is indicated by an "X" in the space that is adjacent to the "Satisfactory" selection. Plate Condition Satisfactory condition of the individual cell plates is indicated by an "X" in the space that is adjacent to the "Good" selection. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 46 Bottom Sediment Accumulation An ideal sediment condition is indicated by an "X" in the space that is adjacent to the "None" selection; however, an "X" in the space that is adjacent to the "slight", "white", or "fine" selections also are acceptable. 2g. Verify that the battery acceptance test results are satisfactory through comparison of the data that are recorded on Figure 19, Battery Acceptance Test Data Sheet, with the acceptable values that are listed below: Battery Discharge Rate The acceptable value for the battery discharge rate is that the battery discharge rate must meet the manufacturer's specified battery discharge rate or the battery discharge rate as determined by the Saudi Aramco Design Engineer. NOTE: Batteries may be at less than rated capacity when received from the manufacturer. Unless 100% battery capacity upon delivery is specified, initial battery capacity can be as low as 90% of the battery rating. This capacity will rise to the rated value in normal service after several years of float operation. Battery Discharge Duration The acceptable value for the battery discharge duration is that the time period for the battery discharge rate must meet the manufacturer's specified battery discharge duration or the battery discharge duration as determined by the Saudi Aramco Design Engineer. The battery discharge duration is the time period that it takes for a battery that is under a constant current discharge to reach the specified battery terminal voltage. The specified battery terminal voltage is a value that is equal to the specified average voltage per cell (usually 1.75V) times the number of cells. 3. Verify that the start-up and commissioning results for the Battery Charger Setpoints and Calibration Checks that are listed on Figure 16, DC/UPS System Start-Up and Commissioning Test Results Data Sheet (page 1), are satisfactory. 3a. Verify that the Enclosure Ventilation Fan is properly operating. Satisfactory operation is indicated by an "X" in the Yes column. 3b. The acceptable values of float voltage range from 2.25 to 2.3 volts per cell, or +/- 1.0% of the nominal voltage, as recommended by the equipment manufacturer. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 47 3c. The acceptable values for equalize voltage are +/- 1.0% of the nominal voltage for systems that are rated more than 10 kW. For systems that are 10 kW or less, the acceptable value is +/- 2.0% of nominal voltage. The nominal voltage is the cell open circuit voltage as stated by the equipment manufacturer. 3d. The acceptable value for operation of the End of Charge Condition Alarm is +/- 5.0% of the 1.75 volts per cell setpoint for lead-acid cells and is +/- 5.0% of the 1.10 volts per cell setpoint for nickel-cadmium cells. 3e. The acceptable value for the Low Charger Output Voltage Alarm setpoint is 2.2 volts per cell for lead-acid cells and 1.4 volts per cell for nickel-cadmium cells. 3f. The Ground Detection Alarm should operate when the leakage current exceeds 10.0 milliamps. This is a fixed value that is established by the equipment manufacturer. 3g. The acceptable value for the Charger Overvoltage Alarm setpoint is +/- 10% of the nominal cell voltage, as recommended by the equipment manufacturer. 3h. The acceptable value for the Charger Failure Alarm setpoint is +0, -15% of the nominal cell voltage as recommended by the cell manufacturer. 3i. The acceptable value for the Enclosure Overtemperature Alarm setpoint is +10%, - 0% of the manufacturer's recommended normal operating temperature. 3j. The Equalize Charge Timer should be set such that the actual elapsed time is within _ 10% of the timer setting. 3k. The dc voltmeter (Output) panelmeter indication and the dc ammeter (Output) panelmeter indication should be within +/- 2.0% of the portable voltage and ammeter indication's as applicable. 4. Verify that the start-up and commissioning results for the UPS System that are listed on Figure 16a, DC/UPS System Startup and Commissioning Test Results Data Sheet (page 1), and Figure 16b, DC/UPS System Start-Up and Commissioning Test Results Data Sheet (page 2), are satisfactory. 4a. Verify that the Enclosure Ventilation Fan is properly operating. Satisfactory operation is indicated by an "X" in the Yes column. 4b. Verify that the Output Voltage, Frequency, and Harmonic Waveforms that are shown in Figure 20 are satisfactory in comparison to the manufacturer's technical data. Satisfactory waveforms are indicated by an "X" in the Yes column. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 48 4c. The acceptable High Inverter dc Input Voltage Alarm setpoint is +10%, -0% of the nominal inverter input voltage. 4d. The acceptable Low Inverter dc Input Voltage Alarm setpoint is +0, -10% of the nominal inverter input voltage. 4e. The Alternate Voltage/Sync Source is Not Available at the Static Switch Alarm setpoint should be set to actuate when the alternate voltage is +/- 10% of its nominal value, or when the alternate source frequency is +/- 5.0% of the nominal 60 Hz. 4f. The Static Switch Position Indicator Alarm should actuate when the static switch transfers to the alternate power source. 4g. The acceptable Inverter Output Failure Indicator setpoint is +/- 10% of the nominal inverter output voltage. 4h. The acceptable Enclosure Overtemperature Indicator setpoint is +10%, -0% of the manufacturer's recommended normal operating temperature. 4i. The acceptable Auto Synchronization Disconnect Alarm setpoint is +/- 5.0% of the alternate voltage source frequency. 4j. The Static Switch Transfer to Alternate Source Voltage should occur at +/- 10% of the nominal inverter output voltage. 4k. The Static Switch Re-Transfer to Preferred Source Voltage should occur at +/- 2.0% of the nominal inverter output voltage. 4l. The Static Switch Transfer to Alternate Source Frequency should occur at +/- 5.0% of the nominal inverter output frequency. 4m. The Static Switch Re-Transfer to Preferred Source Frequency should occur at +/- 2.0% of the nominal inverter output frequency. 4n. The Battery Isolation Circuit Breaker Shunt Trip Monitor voltage should be set to +/- 2.0% of the portable voltmeter indication. 4o. The Inverter dc Input Voltage panelmeter indication should be within +/- 2.0% of the portable voltmeter indication. 4p. The Inverter ac Output Voltage panelmeter indication should be within +/- 2.0% of the portable voltmeter indication. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 49 4q. The Alternate ac Input Voltage panelmeter indication should be within +/- 2.0% of the portable voltmeter indication. 4r. The Inverter ac Output Frequency panelmeter indication should be within +/- 2.0% of the oscilloscope indication. 4s. The Inverter ac Output Amperage panelmeter indication should be within +/- 2.0% of the portable ammeter indication. 4t. Verify that the Manual Bypass Switch transfer to the Test Bypass position is satisfactory. Satisfactory operation of the switch transfer to the Test Bypass position is indicated by an "X" in the Yes column. 4u. Verify that the Manual Bypass Switch transfer to the Full Bypass position is satisfactory. Satisfactory operation of the switch transfer to the Full Bypass position is indicated by an "x" in the Yes column. 4v. (3_ Systems) Verify that the panel Voltmeter Selector Switch function test is satisfactory. Satisfactory operation of each switch function is indicated by an "X" in the Yes column. 4w. (3_ Systems) Verify that the panel Frequency Meter Selector Switch function test is satisfactory. Satisfactory operation of each switch position function is indicated by an "X" in the Yes column. 4x. (3_ Systems) Verify that the panel Ammeter Selector Switch function test is satisfactory. Satisfactory operation of each switch position function is indicated by an "X" in the Yes column. Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 50 DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Page 1) Figure 16a Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 51 DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Page 2) Figure 16b Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 52 Individual Cell Terminal Resistance Test Record Figure 17 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 53 Battery Test Record Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 54 Figure 18 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 55 Battery Acceptance Test Data Sheet Figure 19 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 56 Test Results Data Sheet Waveform Record Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 57 Figure 20 Engineering Encyclopedia Electrical Directing the Start-Up and Commissioning of DC/UPS Systems Saudi Aramco DeskTop Standards 58 GLOSSARY caustic Able to destroy or eat away by chemical action. cell The basic electrochemical unit that is characterized by an anode and a cathode and that is used to receive, store, and deliver electrical energy. corrosive Having the power to corrode a material. electrolysis A chemical action that is caused by the flow of electric current through an electrolyte. electrolyte A conducting medium in which the flow of electric current takes place by migration of ions. hydrometer An instrument that is used to determine the specific gravity of a fluid. meniscus The curved upper surface of a liquid column. The surface is concave when the containing walls are wetted by the liquid and is convex when the containing walls are not wetted. NFPA National Fire Protection Association. open circuit voltage The voltage at a battery's terminals when no current is flowing. parallax The apparent displacement or the difference in apparent direction of an object as seen from two different points that are not on a straight line with the object. pilot cell A cell that is used to provide statistical data about an installation and that is chosen to be representative of the entire battery. root mean square The average root voltage that is applied to an electrical component. (RMS) specific gravity The ratio of the density of a material to the density of pure water, taken as a standard when both densities are obtained by weighing in air.