Battery charge Maintenance

NERC-Compliance Related
This document is NERC-compliance related. Changes could impact compliance
with PRC-005, PRC-011 or PRC-017. All proposed changes to this document
must be reviewed
by Transmission Component Engineering.
1.0 Introduction
Storage batteries are used to supply stored energy for operation of substation
protective relaying and controls. They are kept at a fully charged level by self-
regulated battery chargers that are set to maintain a specific DC bus voltage. The
battery charger can never be relied upon to supply DC current for operating any
protection equipment. This is due to the fact that the fault can easily depress the
charger supply voltage to the point that the charger stops functioning. Failure of the
battery to perform its intended function can result in local service interruption,
significant damage to substation equipment and in some cases wide spread outages
or major system disturbances. Not having adequate battery capacity available at all
times is equivalent to removing relay protection and should be approached with
extreme caution. If in the highly unusual situation where the battery supply must be
disconnected in an energized station, and time is not of the essence, obtain
permission from the supervisor. Prompt attention to any abnormal situation
involving DC systems is essential and maintenance related to batteries and chargers
should be of the highest priority. 2.0 Related Documents MNT-TRMX-00001 MNT-
TRMX-00060 JPL-TRMX-03000 JPL-TRMX-03010 JPL-TRMX-03020 BAS-TRMX-03000
REG-TRMC-00001 REG-TRMF-00002
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MNT-TRMX-00015 Rev. 6 (01/12) Page 2 of 9
3.0 Scope
This procedure defines checks, tests, and settings that are necessary for proper
maintenance of storage batteries and battery chargers. There are multiple tests and
checks that help preserve life and determine the condition of batteries including
periodic cell
voltage and gravity readings as well as cell impedance measurements. Battery
condition can be determined based on all of the testing results along with the
condition of the hardware that make up the complete battery system.
4.0 Safety & Environment
When performing battery maintenance, eye wash solution shall be readily available.
Battery rooms should be well ventilated. Use bicarbonate of soda solution, 1.0 lb
bicarbonate of soda to 1 gallon of water, to neutralize acid spillage. Batteries are
heavy and proper lifting techniques should be employed. Much of the battery work is
done upstream of any
protective breakers or fuses so extreme care should be taken to avoid short circuiting
a single cell or battery set. Keep tools insulated. For the protection of our employees
and the environment, employees should stay abreast of and adhere to all safety
rules, established work practices, and environmental compliance practices while
performing maintenance on this equipment.
5.0 General Information
5.1 Factors That Will Require Attention and Resolution
x Specific gravity reading in a cell or battery out of range.
x A specific cell or battery requiring an excess amount of water to be added. x
Problems with similar batteries in service that are reported by company
personnel or the manufacturer.
x Cell or battery voltage reading out of range.
5.2 Records
x Inspections and maintenance performed to be recorded on apropreate job plan
and retained in accordance with REG-TRMC-00001 or REG-TRMF-00002. x Battery
impedance test and connector resistance test to be recorded and
retained in accordance with REG-TRMC-00001 or REG-TRMF-00002. This is usually
downloadable from the test equipment software.
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MNT-TRMX-00015 Rev. 6 (01/12) Page 3 of 9 5.3 Special Equipment Required
x Hydrometer, battery thermometer, distilled water, funnel, battery grease,
impedance test set, baking soda.
6.0 Battery Visual Inspection
6.1 Verify that battery box is in good condition
x Inspect the locks, lid, hinges, cable supports and rails to be in good condition.
Repair as necessary.
x Inspect any fuse blocks, fuses and cables for corrosion, loose connections and
deteriorated fuse barrels. Repair as necessary.
6.2 Verify that battery room and rack is in good condition.
x Inspect the room to be clean and free of peeling paint. Clean and repair as
necessary.
x Inspect the room lighting and ventilation to be functioning correctly. Clean and
repair as necessary.
x Inspect the rack to be clean, free of corrosion, stable and able to support the
battery weight. Clean and repair as necessary.
6.3 Battery Physical Condition Inspection
x Inspect battery to be clean, case has no cracks, no leaks and tops are dry and not
lifting. Clean and repair as necessary.
x For clear cases inspect the plates for warping and excessive sedimentation.
Document any abnormal conditions.
x Inspect battery straps to be free of corrosion. Clean and repair as necessary. Note:
Strap repair replacement is Relay responsibility for Carolinas and
Substation Electrician responsibility for Florida. For batteries with two-hole post, the
two straps should be installed one above the other on separate bolts. This allows one
strap to be removed at a time for cleaning or replacement without interrupting the
DC supply.
x Inspect battery terminal connections to be free of corrosion. Clean and repair as
necessary.
Note: Terminal repair replacement is Relay responsibility for Carolinas and Substation
Electrician responsibility for Florida.
x Coat all cleaned or replacement connectors, posts, and hardware with a thin film of
no-oxide grease.
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MNT-TRMX-00015 Rev. 6 (01/12) Page 4 of 9 x Torque all battery connections to 70
inch-pounds unless manufacturer specifically
requires a different torque value.
7.0 Battery Electrical Condition Measurements
7.1 Battery Specific Gravity Checks
x Read and record the specific gravity of all cells. Check specific gravity before adding
water. Refer to manufacture’s literature for specific gravity values. If cell specific
gravity values are not within the proper range correct as necessary. If manufacture’s
recommended values are not known then the acceptable values for fully charged
lead acid batteries are 1.210 – 1.300.
x Read and record pilot cell temperature.
Add .001 to gravity readings for each 3ºF above 77ºF.
Subtract .001 from gravity readings for each 3ºF below 77ºF. 7.2 Battery voltage
Checks
x Read and record cell voltages. Refer to manufacture’s literature for correct cell
voltages. Be aware that float voltages vary per lead-alloy composition (for example:
lead-antimony vs. lead-calcium), per manufacturer, and per electrolyte composition
(SG).If manufacture’s recommended values are not known then the acceptable open
circuit voltages for fully charged lead acid batteries are 2.05 – 2.15 VDC. If cell
voltages are not within the proper range correct as necessary. The open circuit
voltage and specific gravity are related by the formula below.
OCV = S.G. + 0.845 7.3 Float Voltage Levels
x Acceptable voltage values for fully charged lead acid batteries
1-cell 24-cell 60-cell
lead-antimony 2.15 - 2.17 51.6 - 52 129 - 130 lead-calcium 2.2 - 2.3 52.8 - 55.2 132 -
138 re-combination* 2.27 54.5 136.2 lead selenium 2.25 54.0 135.0
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MNT-TRMX-00015 Rev. 6 (01/12) Page 5 of 9 7.4 Equalize Voltage Levels
x Acceptable voltage values for fully charged lead acid batteries
1-cell 24-cell 60-cell
lead-antimony 2.33 - 2.35 56 - 56.5 140 - 141 lead-calcium 2.33 - 2.35 56 - 56.5 140 -
141 re-combination* N/A N/A N/A lead selenium 2.35 56.4 141.0 *re-combination
battery must never exceed 2.4 v/cell
7.5 Battery Impedance Test
x Measure and record the internal impedance of each battery cell along with the
ambient and cell temperatures. The battery should be fully charged and being kept
at the float voltage by the charger.
x The internal impedance of each cell should be within ± 20% of the average of all
cells. Notify supervisor to determine if cell or cells should be replaced.
x Deteriorating cells are identified by their higher than average impedance. 7.6
Connector Resistance
x Measure and record the resistance of the terminal connections and inter-cell
connectors.
x Measured values should be ” 0.1 milli-ohm.
x Torque and/or clean connections or replace strap when resistance reading is
abnormal.
x Coat all cleaned or replacement connectors, posts, and hardware with a thin film of
no-oxide grease.
7.7 Battery Capacity Test (nuclear facilities only) Per NEIL STANDARD 14.C.3
Initially within the first two years of installation, then every five years until 85% of
service life or signs of degradation (see IEEE 450-1995) occur, then annually. Replace
battery if capacity is less than 80% of manufacturer's nameplate. Replacement shall
be made within one year.
Battery capacity testing is not part of PE’s NERC battery maintenance program but is
a requirement of the insurance carrier Nuclear Electric Insurance Limited (NEIL).
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MNT-TRMX-00015 Rev. 6 (01/12) Page 6 of 9
8.0 Charger
x Perform visual and mechanical Inspection of the charger to ensure all wiring and
components are in good condition and electrical connections are tight.
x Set float and equalize levels as per 6.2 and 6.3.
x Set current limiter to maximum of 140 percent of charger rated DC current. x Check
operation of electromechanical equalize timer. Verify that the equalize
charging is stopped before the timer motor is turned off.
x Verify that the charger is labeled with the correct float voltage. x Verify correct
reading of volt and ammeter.
x Check DC ripple voltage on chargers with filtering sections. Ripple should be 30
milli-volts or less.
9.0 Battery Alarm
x Set under voltage alarm to 50 volts on 48 volt system and 125 volts on 125 volt
system.
x Check operation of local and remote alarm as applicable.
x If applicable, verify DC voltage reading at the Energy Control center is correct.
10.0 General Checks
x Read and record charger current and float voltage.
x Read and record equalize current and voltage. This is not necessary if battery
manufacturer states that the specific model of battery does not require an equalizing
charge.
x Check DC system for grounds. Repair or report as necessary.
x Add distilled water to bring cell electrolyte levels to the max fill line. Clean tops of
batteries with distilled water after reinstalling caps; wipe down with damp cloth.
Leave battery tops dry.
x Inspect any main DC distribution panels and fuses. Verify that fuses are not warped,
bulged, loose or corroded.
x Inspect any main DC distribution molded case circuit breakers and connections that
are accessible. It is not intended that panel fronts be removed.
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MNT-TRMX-00015 Rev. 6 (01/12) Page 7 of 9
11.0 TERMS AND DEFINITIONS
Acceptance Test: A constant-current capacity test made on a new battery to
determine that it
meets the manufacturer’s rating.
Ampere-Hour (Ah) Capacity: Rated capacity in Ampere-hour (or Watt-Hour)
assigned by the
manufacturer for a given discharge time at a specified electrolyte temperature and
specific gravity to a given end of discharge voltage. It indicates the ability to supply a
given current for a given period of time at a given temperature while maintaining
voltage above a given minimum value. Most Ampere-Hour (Ah) nominal ratings of
stationary battery cells for utility applications are specified with an 8-hour discharge
rate to 1.75 volts per cell (vpc). Refer to manufacturer’s discharge rate tables for
ampere values at various periods of time.
Capacity Test: A discharge of a battery to a designated terminal voltage. See
acceptance test
and performance test.
Electrolyte: The conducting medium, in which the electricity flows within the
cell of a battery, and
which supports the chemical reactions required. Electrolyte in lead-acid battery cells
is a dilute solution of sulfuric acid and water.
Equalizing voltage: The voltage, higher than float, applied to a battery to
correct inequalities
among battery cells (voltage or specific gravity).
Flame Arrestor: This is a porous filter grayish in color normally located on top of
vented lead acid cell jars. It allows for filling the cell with water and prevents external
sparks or flames from igniting internal cell gases.
Float voltage: The voltage applied to a battery to maintain it in a fully charged
condition during
normal operation.
Flooded Cell: A cell in which the products of electrolysis and evaporation are
allowed to escape
to the atmosphere as they are generated. These batteries are also referred to as
“vented.” See Vented Lead Acid Cell.
Individual Cell Voltage (ICV): The voltage measured across one cell in a multi-
celled battery.
Inter-cell Connection Resistance: The total electrical resistance of the
connection between the
terminals of two cells that are electrically connected to each other. It includes the
resistance of the connector and the contact resistance at the point(s) of connection
to the cell terminals.
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MNT-TRMX-00015 Rev. 6 (01/12) Page 8 of 9
Lead Acid Cell: A cell in which the electrodes are made of lead and the
electrolyte is a solution of
sulfuric acid in water. Lead-acid cells include pure lead cells (also called Planté plate
cells) and lead alloy cells such as lead-antimony, lead-calcium, lead-selenium, etc.
Lead-Antimony Cell: A lead-acid cell with plates or grids made from a lead-
antimony alloy.
Lead-Calcium Cell: A lead-acid cell with plates or grids made from a lead-
calcium alloy.
Lead-Selenium Cell: A lead-acid cell with plates or grids made from a lead-
antimony alloy to
which selenium has been added.
Negative Plate: The lead plate negative electrode immersed in electrolyte from
which electrons
flow (through the external circuit) to the positive terminal, when the cell discharges.
At the negative plate the spongy lead (Pb) active material is converted on discharge
to lead sulfate (PbSO4) with the “production” of electrons. Negative plates are thin,
of clean grey or lead color and are always the outside plate.
No-Oxide Grease: Grease used to prevent corrosion and oxidation.
Non-sparking tools: A tool that is non-sparking, non-magnetic, and non-
corrosive specifically to
be used when working on batteries.
Performance Test: A constant-current capacity test made on a battery after
being placed in
service, to detect any change in the capacity determined by the acceptance test.
Pilot Cell: Cell in a battery usually selected to become an indicator of the
general condition of the
entire battery. The pilot cell readings serve as an interim indicator between regularly
scheduled voltage and gravity readings of the complete battery.
Positive Plate: The lead plate positive electrode immersed in electrolyte to
which electrons flow
from the external circuit when the cell is discharging. At the positive plate, the lead
dioxide (PbO2) active material is converted on discharge to lead sulfate (PbSO4) with
the “consumption” of electrons. Positive plates are thicker and of chocolate brown or
black color.
Secondary Cell: An electrochemical cell that can be charged and discharged a
number of times.
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MNT-TRMX-00015 Rev. 6 (01/12) Page 9 of 9
Secondary Battery: A set of secondary cells connected together electrically.
Sediment: The active material which separates from the battery plates and falls
to the bottom of
the jar.
Specific Gravity: The ratio of the weight of a given volume of electrolyte to the
weight of an equal
volume of water at a specified temperature. This temperature is 77° F (25°C). Pure
water has a specific gravity of 1.000.
Station Battery: A stationary battery specifically used at a substation station or
power plant to
supply emergency dc power to critical electrical equipment. Most of the Station
batteries have a nominal voltage of 125 Volt, or 48 Volt and typically consist of 60/24
cells connected in series, with each cell nominally rated 2.08Volts.
Stationary Battery: A secondary battery designed for service in a permanent
location.
Thermal Runaway: The event relating to VRLA batteries whereby the negative
post of the battery
cell exceeds 105°F.
Valve Regulated Lead Acid (VRLA) Cell: Battery cell that is sealed and has a
small pressure
controlled valve that keeps gases from leaving the cell unless the internal pressures
exceed a set value. A major difference with the flooded design is that the VRLA does
not have any free-floating electrolyte; the electrolyte is suspended in either an
absorbing glass mat (AGM) or a gel substance (GEL), which contributes to its more
common name of “gel cell”. It is also referred to as Recombination Cell.
Vented Lead Acid Cell: Also called Flooded Cell or Wet Cell. A cell design which
is characterized