OPERATION AND MAINTENANCE

OF BATTERY SET

1. WHY BATTERY SET IS REQUIRED IN SUB- STATION.

DC voltage is most stable and reliable in nature for which the control and protection
circuits in sub station and power stations are designed to work on D C supply. The DC voltage
is obtained either from Battery Set or from the charger by the use of rectifier unit (Conversion
of AC supply to corresponding DC supply). Maximum time DC voltage is obtained from
Rectifier Unit Charger. But during the emergency condition like failure of AC supply,
maintenance/modification of charger unit etc. to obtain the DC voltage, Battery Set is required.
Moreover it is also required for emergency lighting in the system, when there is a total failure
of AC supply.

2. BASIC WORKING PRINCIPLE OF BATTERY SET AND CHARGER.

A. Supply of Dc voltage from the Battery Set.

When AC supply is made OFF or for non-availability of AC supply to the battery

charger, the load terminals are connected directly to the battery terminals through contactor
DC1 (Refer Block diagram). For such condition, coil of the contactor (DC1) gets supply from
battery and closes the contactor (DC 1) and allows the extension of supply to the load
terminals. At the same time blocker diode (BD3) being in reverse bias condition, behaves like
open circuit and separates the direct connection between the tap cell and + ve terminal of the
battery.

B. Float charge mode.

For such mode, the transformer rectifier module (float) functions and provides DC out
put voltage to the load directly. At the same time contactor (DC1) also gets close for float
charging of battery set from the charger.

In modern battery charger system different additional facilities like FLOAT charge in
manual mode, AUTO mode etc.. are also available. These functions work on by PCB control
circuits.

C. Boost charge mode.

For such mode, the transformer rectifier module (Boost) functions and provides DC out
put voltage to the battery terminals directly. During this mode contactor (DC1) does not
operate, so blocking diode (BD3) becomes forward and supplies the battery voltage to the load
terminals from @Tap Cell connection.
 BLOCK DIAGRAM OF CHARGER + BATTERY SET

Index :- 1- MCCB FOR FLOAT CHARGER.

2- MCCB FOR BOOST CHARGER
3- TRANSFORMER RECTIFIER MODULE (FLOAT)
4- TRANSFORMER RECTIFIER MODULE (BOOST)
5- BLOCKER DIODE (FLOAT)
6- BLOCKER DIODE (BOOST)
7- OUT PUT MCCB FOR FLOAT CHARGER.
8- OUT PUT MCCB FOR BOOST CHARGER.
9- DC CONTACTOR (DC1)
10- BLOCKER DIODE (BD3)

@ Tap Cell Connection

Generally 84th cell or 92nd cell is connected as the Tap Cell Connection in the battery
system as per the design of the battery system. But most of the battery set, 84th cell connection
is taken as the tap cell connection.

Function of Tap Cell Connection

It plays the role during “ BOOST CHARGE” mode of the charger. During this
condition, the battery voltage becomes as high as 2.6 V/cell at higher charging current. So, to
avoid high voltage connection (2.6x110= 286 V) to the load, the tap cell connection facility is
provided in the charger system. Due to this arrangement reduced voltage (2.6x84 = 218 V)
becomes available across the load circuit.

In modern battery charger system different additional facilities like BOOST CHARGE,
FLOAT CUM BOOST CHARGE in both MANUAL and AUTO mode are also available. As
per the requirement of charging current and voltage, the corresponding values can be fed from
the charger. These functions work on by PCB control circuits.
 3. BASIC CHEMICAL REACTION IN LEAD –ACID BATTERIES
In grid S/S, Lead Acid Batteries of $200/300 AH capacity are generally used. In major
132 KV S/S and all 220 KV, 400 KV S/S, 2 sets of Batteries with 2 sets of chargers are
generally provided.

In Lead Acid Batteries the +ve plates are lead peroxide (PbO2) and – ve plates are
purely sponge lead ( Pb) and these materials are porous in nature having the qualities similar
to sponge. These materials ( +ve and – ve plates ) are filled with electrolyte ( Battery solution
:- combination of Sulphuric acid and water )

$ 300 AH Capacity

If battery set is allowed to be discharged at the rate of 30 Ampere, then it will take 10
Hrs to discharge completely to end voltage of 1.85 V and sp. Gravity of 1180 to 1190.

PbO2 + H2SO4 + 2H+ + 2e - Pb SO4 + 2 H2O

Pb + SO42- Pb SO4 + 2e –

PbO2 + Pb+ 2 H2SO4 2 Pb SO4 + 2 H2O

In a fully charged battery, all the acid remains in electrolyte and result maximum
specific gravity. As the battery continues to discharge, the acid in the electrolyte form the
chemical reaction with active materials and result the chemical compound of Pb SO4 and water
(H2O). So specific gravity falls due to this decrease of acid in electrolyte and increase of water.

When the battery is again charged, the reverse reaction takes place. The acid in the
lead sulphate is driven out and comes back to electrolyte. The return of the acid again increases
the sp.gravity of the electrolyte. When all the acid is returned to electrolyte, further charging
will not raise the specific gravity of the electrolyte i.e the material of the plate are again lead
peroxide and lead with sp.gravity maximum. But if further charging is done, then the water in
the electrolyte will decompose to hydrogen and oxygen gas, which will be liberated in the form
of gases. Even if in the normal charging/discharging process, these gases (H2, O2) are also
liberated, which in turn reduces the level of electrolyte. So, extra addition of the distilled water
is required to maintain the proper level of electrolyte.
4. SOME IMPORTANT DATA AND TERMS.
Sl. DATA/PARTICULARS VALUES
No.
1 RECOMMENDED END VOLTAGE 1.85/CELL
2 SP. GRAVITY (FULLY CHARGED) 1200 AT 27 0 C
3 SP. GRAVITY (FULLY DISCHARGED) 1190 AT 27 0 C
4 ALLOWABLE DIFF. IN MAX & MIN SP. 30 POINTS /CELL
GRAVITY
5. NORMAL OPERATING VOLTAGE 2.15/CELL
6 FULLY CHARGED VOLTAGE 2.4 –2.5 /CELL
7 Equivalent SP. GRAVITY AT 27 0 C HYDROMETER READING
AT t 0 C + 0.0007 ( t – 27 )
8 RATE OF CHARGING (% AH Rating of Battery) in Amp
1. FINISHING RATE AT 10 HRS 4
2. NORMAL RATE 10
3. EQUALISING CHARGE AT 10 2
HRS
9 FLOAT CHARGE
1. FLOAT CHARGE CURRENT (AH 2) /2400 + Sub Station
Load
2. TICKLE CHARGE CURRENT 50 TO 100 mA / 100 AH Battery
Capacity
3. SET Voltage 2.15 to 2.17 V / Cell

5. IMPORTANT NOTE
1. BATTERY SHOULD BE NORMALLY KEPT ON FLOAT CHARGE

2. EQUALISING CHARGE

1. For FLOAT charge (2.16 to 2.2) / cell, equalizing charge to be given once in 3
months
2. For FLOAT charge (2.06 to 2.16) / cell, equalizing charge to be given once in a
month for 220V Battery

3. BOOST CHARGE

1. Allow BOOST charge after Test Discharge

2. Allow BOOST charge for low sp. Gravity of major cells (below 1190) and low
Voltage (Below 1.9 V

4. CONDITION CHARGE
Discharge the battery to end voltage 1.85 V and again charging is called
CONDITION CHARGING. It should be done once in a year.
6. IMPORTANT TERMS
1. END VOLTAGE: -
As a matter of general principle, when the battery set is allowed to discharge, then end
voltage of each cell should be 1,85 V

2. RATE OF CHARGE: -
Different principle of charging methods are used, according to the requirement of the
charge to the battery set. These are of three methods
• Finishing Rate of charge
• Normal Rate of charge
• Equalizing Charge

FINISHING RATE OF CHARGE: - For this the rate of charging current in ampere is
4% of the AH capacity of the Set at 10 hrs.
NORMAL RATE OF CHARGE: - For this the rate of charging current in ampere is 10
% of the AH capacity of the Set
EQUALIZING CHARGE: - For this the rate of charging current in ampere is 2 % of
the AH capacity of the Set at 10 hrs.

Example: - Suppose Battery Capacity is 300 AH.

Then Finishing Rate of charge= 4% of 300 = 12 Amp
Normal Rate of charge= 10% of 300 =30 Amp
Equalizing Charge = 2% of 300 = 6 Amp

3. EQUIVALENT SP. GRAVITY: -

For comparison of sp.gravity a reference temperature is taken into account. This
temperature is 27 deg. Centigrade. So, to obtain the equivalent sp. Gravity a correction factor is
used with a formula as below.

Equivalent sp. Gravity = Hydrometer reading at t deg. C + 0.0007 ( t-27)

Example: - Suppose Hydrometer reading at 20 deg. C =1.190

Then corresponding Eq. sp. Gravity at 27 deg. C
= 1.190 + 0.0007( 20-27)
= 1.185
7. DISCHRGE METHOD OF BATTERY SET:-
In general there is no any particular method/principle for discharge of the battery set.
The battery set can be discharged at any rate of current, up to which the set can withstand
without harm to the plates. But discharge rate can be preferably taken as 10% of AH capacity
of the cells at constant rate to an end voltage of 1.85V/cell and 1190 sp.gravity, correction to
27 deg. C (As per the clause 12.5 of IS 1051-91)

Use electrode dipping saline water method for discharge of the battery set. The rate of
discharge current can be adjusted by the dipping of electrodes up and down in the saline water
or by the adjustment of different level of saline water. (Fig.2)

FIG NO 2

A. Notes on Discharge of Battery Set

1. Monitor the discharge current for constant discharge of battery set.

2. Before starting of discharge
a. Keep the following materials ready to use during discharge
• Voltmeter
• Hydrometer
• Thermometer
• Pure battery grade distill water( IS 1069) for topping
• Plastic funnel and jug
• Spanner of required size
• Protective clothing (apron, gloves etc...)
• Other first aid set etc
b. Be sure about the status of the charger set, whether capable of providing
boost charge to the battery or not.
c. Record the values as per the table no 1 & 2
 B. During the discharge of the Battery set.

a) Record the values of the cells in the battery set after 2 Hrs of discharge as like
table no 2 with usual norm of discharge current. But closely monitor the
physical status of cells and net voltage reduction in the distribution board. If it
is found with gassing of the cell and quick reduction cell voltage, then stop the
normal discharge rate of current and allow only the 5 % of AH capacity

b) Distinguish the cells, whose voltage and sp.gravity are reducing quickly as
compared to the cells in the set. (MONITOR THESE CELLS WITH HOURLY
READING BASIS). On hourly monitoring basis if the voltage and sp. Gravity
reduces below the norm (1.85V and 1190) then DISCONNECT THOSE CELLS
FROM THE SET and allow the discharge of other cells till to the end voltage of
1.85 V and sp.gravity of 1190 correction to 27 deg. C.

C. IMPORTANT NOTE

a) SOMETIMES WITH NORMAL DISCHARGE CURRENT (10 % OF ah

CAPACITY) OF BATTERY SET, MAXIMUM CELLS IN THE SET
BEHAVE THE STATUS IN DOWN TREND, WITH GAS EVOLUTION
DURING FIRST HOUR OF DISCHARGE AND REDUCTION OF CELL
VOLTAGE AND SP.GRAVITY. FOR SUCH CONDITION, REDUCE THE
DISHARGE RATE TO 5 % AH CAPACITY

b) BUT IN NO CIRCUMSTANCES CONDITION DISCHARGE OF THE

CELL SHOULD BE ALLOWED BELOW THE END VOLTAGE OF 1.85
V/CELL AND SP.GRSVITY OF 1180

i. Reading of Battery charger ( TABLE NO 1 )

TERMINAL FLOAT BOOST FLOAT CUM CHARGER AC

VOLTAGE MODE MODE BOOST SUPPLY OFF
READING MODE CONDITION
+VE AND –VE OF
BATTERY SET
ACROSS LOAD

ACROSS TAPCELL
 ii. Reading of Battery set ( TABLE NO 2 )

Cell Volt Sp.g Spg at Cell Volt Sp.g at Spg at Cell Volt Sp.g at Spg at
No at t0 C 270 C No t0 C 270 C No t0 C 270 C
1 38 75
2 39 76
3 40 77
4 41 78
5 42 79
6 43 80
7 44 81
8 45 82
9 46 83
10 47 84
11 48 85
12 49 86
13 50 87
14 51 88
15 52 89
16 53 90
17 54 91
18 55 92
19 56 93
20 57 94
21 58 95
22 59 96
23 60 97
24 61 98
25 62 99
26 63 100
27 64 101
28 65 102
29 66 103
30 67 104
31 68 105
32 69 106
33 70 107
34 71 108
35 72 109
36 73 110
37 74
8. RECHARGING METHOD OF BATTERY SET
Immediately after the discharge of the set, recharging should be followed. Whenever
the manufacturer’s instructions are available for charging of the battery set, then the same may
be followed. In absence of the manufacturer’s instructions the following may be followed.

a) Discharged battery set should be charged at normal rate of charge current (10 %
of AH capacity) in BOOST MODE (preferably in MANNUAL MODE) Allow
this charging current till the cells start gassing on or attain the voltage of 2.3 to
2.4 V /cell. Then reduce the current to the finishing rate ( 4 % of AH capacity )
till the sp.gravity of all the cells to attain 1200, corrected to 27 deg. C. and
remain constant value for three half hourly readings. Gas should be freely
evolved from all the cells and the closed circuit reach a constant value of 2.5 to
2.6 V/cell, which indicate the “FULL CHARGE ‘ condition
b) Allow the battery set and charger in FLOAT MODE either in manual or in
AUTO as per the requirement

A. DURING RECHARGE OF THE SET

a) Take the reading of all the cells as per the table no 2

b) Stop recharge in Normal current method till cell voltage attains 2.3 to 2.4 v/cell
c) Then allow finishing rate of charge till the final voltage as mentioned in the
method
d) Finally keep the battery in FLOAT mode.

B. IMPORTANT NOTE

a) SOMETIMES IT IS SEEN THAT VOLTAGE OF FEW CELLS ATTAIN

THE FINAL CHARGE VOLTAGE OF 2.5 TO 2.6 VOLT/CELL, BUT
SP.GRAVITY DOES NOT COME TO THE REQUIRED VALUE. FOR
SUCH CONDITION, ALLOW THE SET IN FLOAT MODE AND
MONITOR THOSE CELLS WITH 2 HRLY READING. THESE CELLS
WILL TAKE MINIMUM 6 TO 8 HRS FOR RESULTING THE REQUIRED
VALUEOF SP, GRAVITY

IF THE VALUE OF SP. GRAVITY DOSE NOT COME TO 1200, THEN

THOSE ARE REQUIRED TO BE CONDITIONED.
 9. MAINTENANCE

A. GENERAL

a. Keep the cell container, stand and surrounding dry and clean.
b. Keep battery room well ventilated during charging the cells
c. Keep the terminals, intercell / row tiers and take offs nut and bolts tight and
smeared with petroleum jelly or Vaseline to prevent them from corrosion.
d. Should there be any corrosion of the racks, clean the affected parts thoroughly
and protect them from corrosion by coating with acid proof paint and jelly.
e. Keep battery room well lighted. Avoid direct sun light to the set
f. Use battery grade distilled water (IS 1069)
g. Never do the topping up of the cells by means of metal vessels.
h. Keep the vent plugs and acid level indicating float plugs in position and tight.
i. Never allow inflammable articles inside the battery room.
j. Take particular care not to bridge the terminals with spanner while tightening
the terminals.
k. Always use gloves, while working with live battery.

B. MAINTENANCE SCHEDULE

PERIODI ITEMS TO BE PERIODICI ITEMS TO BE CHECKED

CITY CHECKED TY
1. Measure and record 1. Sp. Gravity, Voltage of each
DAILY the $$pilot cell MONTH cell and electrolyte Temp. (
(Use daily Voltage, Sp. Gravity LY Table No 2 )
record & Electrolyte 2. Give Equalizing Charge
table ) Temperature 3. Switch off Charger and test
2. Battery Voltage by tripping/ closing of any one
Switching off feeder from Battery Source
Charger 4. Check all connection of battery
3. Hourly reading DC and Charger
Voltage, Charger out
put current and
Trickle Charge
Current
1. Cleaning of
WEEK terminals, topping up YEAR 1. Allow Condition Charging
LY distilled water if LY
required
2. Review pilot cell
reading and adjust
the trickle charge
current if required
10. BATTAERY SYMPOTOMS AND REMEDIES
SYMPTOMS
1. Corrosion
2 Sulphation
• Under Charging
• Over Discharge
• Too strong /Weak Acid
• Too Rapid Discharge
• Short Circuit
• Plate Exposed to Air
3.Shedding of Active Material
• Over charging of Plates
• Charging done at high rate
• Defective material
• Improper application of Material on
plate
4.Over Charging
• Excessive Gassing
• Deterioration of Active material
from +ve plate
• Temp. rise
• Bending of Plates
5.Under Charging
• Low sp. Gravity
• Change of the colour of plate.
• Deterioration of Active material
from +ve plate
• Bending of Plates
6.Abnormal reduction of Capacity
• Abnormal drop of voltage
• Sulphur formation
• Development of pores in lead
sponge
• Loss of active material
• Loss of electrolyte
7.Buckling or Bending of plates
• Discharge at rapid rate.
• Unequal distribution of current
• Defective plates
REMEDIES
1. Remove Electrolyte
2. Pour Distill Water
3. Refill with New Electrolyte
1. Initial stage, repeat the low rate charging
and Discharging.
2. Latter stage, Special treatment should be
provided
1. Maintain the proper charging and
discharging limits
(2.4V for charging and 1.85V for
discharge)
1200 sp. Gravity – charging
1190 sp. Gravity - discharging
1. Reduce the Charging Rate and add
distilled water to attain the sp. Gravity of
1200.
1. Increase the Charging Rate to attain the
sp. Gravity of 1200.
1. Allow proper charging and discharging
method
2. Contact manufacturer for replacement
1. Allow proper charging and discharging
method
2. Contact manufacturer for replacement
 • Direct discharge
• Expansion of plates
8.Reversal of negative plate Use correct electrolyte and charge the cell
• It results due to connection of weak or replace with a good one.
cell in the set, its discharge is ended
before the other cells and causes the
reversal of negative plate.
9.Internal Discharger Local Action Use correct electrolyte and charge the cell
• Gassing of the cells even under idle or replace with a good one.
condition
• Abnormal gassing in charge
condition
• Reduction of Battery capacity
10. Hardening of – ve in Air Pour distilled water and proper electrolyte
• Oxidation and heating in Air or and cover the plates in proper manner
exposed plates

$$ PILOT CELL-

Pilot cells are chosen in a group. This group may be of 10 or 20 in numbers. But in
general 10 no group is maintained as pilot cell. For the set of 10 no group, the cells are taken as
cell no1 from first group, cell no11 from second group etc (the cells are chosen no1,
11,21,31,41,51, 61,71,81,91,101). Similarly for the next month or for the next period, next
succeeding cells are chosen (cell no 2,12,22,32,42, 52,62,72,82,92,102). This method of
selection continues till all the cells are covered under pilot cells
 DAILY RECORD TABLE
DAY

DATE/TIME

SL.NO RECORDS VALUES

1 BATTERY FLOAT VOLTAGE

2 BATTERY VOLTAGE WITH CHARGER OFF COONDITION

3 PILOT CELL READING

CELL NO SP. GRAVITY AT T0 C SP. GRAVITY AT 270 C VOLTAGE

4 HOURLY READING OF DC VOLTAGE

01HRS 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24HRS
PREPARED BY
PREPARED BY