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LARSEN & TOUBRO LIMITED

CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C


PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 1 of 11
No.

CONTENTS

1. OBJECTIVE

2. RFERENCE

3. PRE-REQUISITES

4. PRECAUTION AND NOTES

5. TEST EQUIPMENT

6. COMMISSIONING AND TESTING PROCEDURE

7. CHECKLIST
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 2 of 11
No.

1. OBJECTIVE

The objective of this procedure is to provide guidelines to commission


Tabular Low Maintenance Lead Acid Batteries

2. REFERNCE
2.1 GA Drawing of Battery room Layout
2.2 GA Drawing of Battery Arrangement Drawing
2.3 Schematics for Battery connections.

3. PRE REQUISITES

3.1 Lighting is available in the battery and battery charger room


3.2 Earthing of the Battery Charger Panels.
3.3 Availability of ventilation fans with temporary power supply.
(Permanent supply shall be restored once SWGR and MCC’s are
commissioned.)
3.4 All civil works are completed.
3.5 Agreement upon erection Punch points.
3.6 Input supply to the battery charger 415V, 3Ph
3.7 Battery discharge resistor and control panel.
3.8 DG set of minimum 125KVA. (Alternate power supply to charge the
battery)
3.9 Eye Wash provision.
3.10 MSDS ( Material Safety Data Sheet) for electrolyte.
3.11 All gadgets, aprons, gloves, eye protective goggles, etc for handling
electrolyte as MSDS.

4. PRECAUTION AND NOTES

4.1 Area under commissioning shall be completely tagged with


commissioning tags.
4.2 To protect personnel and the equipment in the area of commissioning,
area restrictions, etc. shall be displayed.
4.3 Prior to the commencement of the commissioning, the total area around
the equipment is to be totally cleaned.
4.4 Sulphuric Acid is highly corrosive and hazardous to human life, It should
be handled with due care.
4.5 Ensure proper ventilation in battery room.
4.6 Never add water in to sulphuric acid to prepare electrolyte. Always add
sulphuric acid in to water.
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 3 of 11
No.

4.7 During preparation and filling use required personal protective


equipments like rubber gloves, Gumshoes, eye goggles, Plastic apron.
Eyewash and fire extinguisher as per MSDS should be available during
the commissioning.
4.8 Keep MSDS (Material Safety Data Sheet) ready for Sulphuric acid and
follow the instruction during commissioning.
http://www.cyb.com.au/automotive/msds/MSDS%20Batt%20Fluid%20A
cid%20Rev2.pdf
http://www.cometchemical.com/MSDS/SulphuricAcid.DOC

6. TEST EQUIPMENT

- 1. Digital Multimeter
- 2. Hydrometer
- 3. Resistive load
- 4. Thermometer
7. TESTING AND COMMISSIONING PROCEDURE

BATTERY INSTALLATION:

1. The battery should be installed in a cool and dry location

2. Provide a free space on all the sides of the battery for easy assembly and
carrying out periodic checks

3. Place the mounting frame on the ground and ensure that it is in correct
position and uniform level. Use shims if required

4. The cell insulators shall be first placed on the stand and then cell should be
assembled on the four insulators. Level and distance between cells to be
maintained as per the drawing.

5. Check battery polarities before connections

6. A layer of petroleum jelly shall be applied after the connection to avoid


corrosion

Caution: 1. Do not short the positive and negative terminals


2. During installation, ensure that the connectors do not drop as they
may fall on the other terminals, and lead to short circuit.
3.After connecting all inter cell connectors / cables, ensure that the
connections are tight.
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 4 of 11
No.

Electrolyte and filling:


Sulphuric acid used for electrolyte shall confirm to IS 266. Specific gravity of
the electrolyte should be 1.180 + 0.005 at 27 Degree. If electrolyte is
required to be prepare at site, than never use glass or plastic container
because heat generated during the process is very high. Lead lined wooden
container is recommended for the purpose. During the preparation never
add water in the acid container. Add acid slowly in to the water filled
container. Apply temperature correction factor to get the corrected density at
27 Deg, Density required at t deg temperature is
SGt = SG27-0.0007(t-27) Where SGt is specific gravity at t deg
temperature, SG27 is specific gravity at 27 deg temperature, t is actual
temperature at site.

Estimate quantity of electrolyte with help of data sheet. The quantity


required per cell is mentioned in the data sheet. Never dispose the
electrolyte directly in storm water drain, as it is violation of environmental
law. Disposal of Electrolyte shall be done as per the guidelines given by
safety manager and manufacturer.

Once the electrolyte is ready and wait till it is cooled down, fill the cell up to
the MAX mark of the battery. Use glass or plastic jars for filling. After filling
the cells allow cells for around 8-12 hours for soaking. During the process
level of electrolyte goes down. Restore the Max level by adding the
electrolyte.

Initial Charging:
Ensure that charger is commissioned as per the procedure and connect the
cables as per diagram keeping polarity in to consideration.
Clean and wipe the place and check the connection tightness.
Check polarity and record of the cell voltage, bank voltage, specific gravity
before starting the charge.
First charging to be started after end of soaking period and when electrolyte
cools down to ambient temperature. It is essential to start the first charging
within 24 hours of filling.
The charging should be done at a constant current of 0.1 C10 till the
cell voltages reaches, 2.4. After reaching 2.4 volts, the charging
current to be reduced to 0.5 C10. Once the cell voltages reaches 2.60
to 2.75, stop the charging of battery.

Monitoring during initial charging:


1) Check polarity and record of the cell voltage, bank voltage, specific
gravity before starting the charge.
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 5 of 11
No.

2) At the end of each hour record the current and battery cell voltages.
Ensure that it is as per the charging requirement as mentioned above.
3) Record specific gravity and temperature of electrolyte, If temperature
is beyond 50 Deg C, discontinue the charging and restart only after
temperature reaches 40 Deg C
4) After 80% of the total AH input is given take hourly reading of voltage
and specific gravity. IF number of cells are more select few pilot cells for the
purpose.
5) At the end of the charge cycle gravity should 1.2 + 0.005 at 27
Degree. If any cell does not attain the charge (gravity is considerably less)
refer Battery manual.

At the end of the initial charging, adjust the level and gravity of cell to 1.2 +
0.005 at 27 Degree. Clean and wipe the place, Ensure connection tightness.

Operational setting:
After completing the first charging, set the charger to operate the battery for
normal float charging, Keep voltage between 2.15 to 2.2 and current as per
the data sheet.
Switch of the charger and keep the battery in open circuit for around 12
hours (not more than 24 hours) and than start the discharge capacity test.

Discharge capacity test:


1) Ensure that battery is in full charge condition by measuring voltage and
gravity of each cell
2) Connect external resistance load and discharge the battery with 0.1 C10
discharge current.
3) Monitor the voltage of all cells, gravity and temperature of pilot cells
4) Record the cell voltage more frequently after 8 hour typically at every 15
minute.
5) The discharge shall be terminated if any of the cell voltage reaches to
1.85V.
6) The time from beginning to end of the discharge shall be taken as period
of discharge.
7) Average electrolyte temperature of pilot cells to be noted and actual
capacity at 27 Deg C shall be noted as

The following formula shall be used to calculate the actual discharge


capacity of cell from the recorded results which represents the actual
discharge at the ambient temperature. This results shall be corrected to the
design electrolyte temperature by using the formula
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 6 of 11
No.

Ca= (Ct + ( Ct*R*(27-t)/100) , Where


Ct = observed capacity (Amp X Hours)
R =Variation factor at a given rate of discharge (0.43 for C10 discharge)
‘t = Average room temperature in C

Compare The AH capacity with rated capacity

There are two formats for recordings during monitoring.


1) First format while voltage and gravity both are required to be measured
and recorded.
2) Second format is for only voltage is to be monitored and gravity of the
pilot cell is required to be monitor.
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 7 of 11
No.

8. Erection completion checklist

a. Completeness of installation as below


All cells in position : OK / NOT OK
Connection as per polarity marking : OK / NOT OK
Intercell connections : OK / NOT OK
Interrow connections : OK / NOT OK
Interbank connections : OK / NOT OK
End take off connections : OK / NOT OK
c. Ensuring tightness of all connections : OK / NOT OK
d. Ensuring easy accessibility of cells : OK / NOT OK
e. Ensuring cleanliness of battery room : OK / NOT OK
f. Ensuring proper ventilation : OK / NOT OK
h. Ensuring availability of safety materials e.g. gloves : OK / NOT OK
i. Inspection of each cell as below:
No physical damage to contaners, : OK / NOT OK
plates etc.
j. Ensure polarity and connection of outgoing leads : OK / NOT OK
K. Cleanliness of the room : OK / NOT OK

Tested by Witness by Witness By


Larsen & Toubro Ltd. Tata Consulting VPGL
Engineers
Name: Name: Name:

Signature Signature Signature


LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 8 of 11
No.

Date: Time: Battery Rating:


Total Voltage: Current:
Pilot cell 1 Temp: Pilot cell 2 Temp: Pilot cell 3 Temp:
Cell Parameter Cell Parameter Cell No Parameter
No. No.
1 Voltage 25 Voltage 49 Voltage
Gravity Gravity Gravity
2 Voltage 26 Voltage 50 Voltage
Gravity Gravity Gravity
3 Voltage 27 Voltage 51 Voltage
Gravity Gravity Gravity
4 Voltage 28 Voltage 52 Voltage
Gravity Gravity Gravity
5 Voltage 29 Voltage 53 Voltage
Gravity Gravity Gravity
6 Voltage 30 Voltage 54 Voltage
Gravity Gravity Gravity
7 Voltage 31 Voltage 55 Voltage
Gravity Gravity Gravity
8 Voltage 32 Voltage 56 Voltage
Gravity Gravity Gravity
9 Voltage 33 Voltage 57 Voltage
Gravity Gravity Gravity
10 Voltage 34 Voltage 58 Voltage
Gravity Gravity Gravity
11 Voltage 35 Voltage 59 Voltage
Gravity Gravity Gravity
12 Voltage 36 Voltage 60 Voltage
Gravity Gravity Gravity
13 Voltage 37 Voltage 61 Voltage
Gravity Gravity Gravity
14 Voltage 38 Voltage 62 Voltage
Gravity Gravity Gravity
15 Voltage 39 Voltage 63 Voltage
Gravity Gravity Gravity
16 Voltage 40 Voltage 64 Voltage
Gravity Gravity Gravity
17 Voltage 41 Voltage 65 Voltage
Gravity Gravity Gravity
18 Voltage 42 Voltage 66 Voltage
Gravity Gravity Gravity
19 Voltage 43 Voltage 67 Voltage
Gravity Gravity Gravity
20 Voltage 44 Voltage 68 Voltage
Gravity Gravity Gravity
21 Voltage 45 Voltage 69 Voltage
Gravity Gravity Gravity
22 Voltage 46 Voltage 70 Voltage
Gravity Gravity Gravity
23 Voltage 47 Voltage 71 Voltage
Gravity Gravity Gravity
24 Voltage 48 Voltage 72 Voltage
Gravity Gravity Gravity
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 9 of 11
No.

Pilot cell 1 Temp: Pilot cell 2 Temp: Pilot cell


3 Temp:
Cell Parameter Cell Parameter Cell No Parameter
No. No.
73 Voltage 97. Voltage 121. Voltage
Gravity Gravity Gravity
74 Voltage 98. Voltage 122. Voltage
Gravity Gravity Gravity
75 Voltage 99. Voltage 123. Voltage
Gravity Gravity Gravity
76 Voltage 100. Voltage 124. Voltage
Gravity Gravity Gravity
77 Voltage 101. Voltage 125. Voltage
Gravity Gravity Gravity
78 Voltage 102. Voltage 126. Voltage
Gravity Gravity Gravity
79 Voltage 103. Voltage 127. Voltage
Gravity Gravity Gravity
80 Voltage 104. Voltage 128. Voltage
Gravity Gravity Gravity
81 Voltage 105. Voltage 129. Voltage
Gravity Gravity Gravity
82 Voltage 106. Voltage 130. Voltage
Gravity Gravity Gravity
83 Voltage 107. Voltage 131. Voltage
Gravity Gravity Gravity
84 Voltage 108. Voltage 132. Voltage
Gravity Gravity Gravity
85 Voltage 109. Voltage 133. Voltage
Gravity Gravity Gravity
86 Voltage 110. Voltage 134. Voltage
Gravity Gravity Gravity
87 Voltage 111. Voltage 135. Voltage
Gravity Gravity Gravity
88 Voltage 112. Voltage 136. Voltage
Gravity Gravity Gravity
89 Voltage 113. Voltage 137. Voltage
Gravity Gravity Gravity
90 Voltage 114. Voltage 138. Voltage
Gravity Gravity Gravity
91 Voltage 115. Voltage 139. Voltage
Gravity Gravity Gravity
92 Voltage 116. Voltage 140. Voltage
Gravity Gravity Gravity
93 Voltage 117. Voltage 141. Voltage
Gravity Gravity Gravity
94 Voltage 118. Voltage 142. Voltage
Gravity Gravity Gravity
95 Voltage 119. Voltage 143. Voltage
Gravity Gravity Gravity
96 Voltage 120. Voltage 144. Voltage
Gravity Gravity Gravity
LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 19-03-05
DOC. TITLE Battery commissioning Procedure Page 10 of 11
No.

Pilot cell 1 Temp: Pilot cell 2 Temp: Pilot cell 3 Temp:


Cell Parameter Cell Parameter Cell No Parameter
No. No.
145 Voltage 157 Voltage 169 Voltage
Gravity Gravity Gravity
146 Voltage 158 Voltage 170 Voltage
Gravity Gravity Gravity
147 Voltage 159 Voltage 171 Voltage
Gravity Gravity Gravity
148 Voltage 160 Voltage 172 Voltage
Gravity Gravity Gravity
149 Voltage 161 Voltage 173 Voltage
Gravity Gravity Gravity
150 Voltage 162 Voltage 174 Voltage
Gravity Gravity Gravity
151 Voltage 163 Voltage 175 Voltage
Gravity Gravity Gravity
152 Voltage 164 Voltage 176 Voltage
Gravity Gravity Gravity
153 Voltage 165 Voltage 177 Voltage
Gravity Gravity Gravity
154 Voltage 166 Voltage 178 Voltage
Gravity Gravity Gravity
155 Voltage 167 Voltage 179 Voltage
Gravity Gravity Gravity
156 Voltage 168 Voltage 180 Voltage
Gravity Gravity Gravity

Tested by Witness by Witness By


Larsen & Toubro Ltd. Tata Consulting VPGL
Engineers
Name: Name: Name:

Signature Signature Signature


LARSEN & TOUBRO LIMITED
CLIENT VEMAGIRI POWER GENERATION LTD. Doc.No. VPG/COMNG/ELEC/003/C
PROJECT 388.5 MW combined Cycle Power Plant Revision 0
SYSTEM Station DC System Date 01-02-05
DOC. TITLE Battery commissioning Procedure Page No. 11 of 5

Date: Start Time: End Time: Sheet no: of sheets


Tim Curre Gravit Tem
e nt y of p of
(Amp) pilot pilot
cell cell
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0

Tested by Larsen & Toubro Ltd. Witness by Tata Consulting Engineers Witness By VPGL

Name: Name: Name:

Signature Signature Signature

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