OPERATION AND MAINTENANCE PRACTICE OF STATION BATTERY SET WITH CASE STUDIES ON DC LEAKAGE IN THE SYSTEM

1. WHY BATTERY SET IS REQUIRED IN SUBSTATION. 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 nonavailability 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. 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

C.

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. No. 1 2 3 4 5. 6 7 DATA/PARTICULARS RECOMMENDED END VOLTAGE SP. GRAVITY (FULLY CHARGED) SP. GRAVITY (FULLY DISCHARGED) ALLOWABLE DIFF. IN MAX & MIN SP. GRAVITY NORMAL OPERATING VOLTAGE FULLY CHARGED VOLTAGE Equivalent SP. GRAVITY AT 27 0 C RATE OF CHARGING 1. FINISHING RATE AT 10 HRS 2. NORMAL RATE 3. EQUALISING CHARGE AT 10 HRS FLOAT CHARGE 1. FLOAT CHARGE CURRENT 2. TICKLE CHARGE CURRENT 3. SET Voltage 5. IMPORTANT NOTE 1. BATTERY SHOULD BE KEPT ON FLOAT CHARGE EQUALISING CHARGE VALUES 1.85/CELL 1200 AT 27 0 C 1190 AT 27 0 C 30 POINTS /CELL 2.15/CELL 2.4 2.5 /CELL HYDROMETER READING AT t 0 C + 0.0007 ( t 27 ) (% AH Rating of Battery) in Amp 4 10 2 (AH 2) /2400 + Sub Station Load 50 TO 100 mA / 100 AH Battery Capacity 2.15 to 2.17 V / Cell NORMALLY

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 BOOST CHARGE Allow BOOST charge after Test Discharge

4.

2. Allow BOOST charge for low sp. Gravity of major cells (below 1190) and low Voltage (Below 1..9 V) 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

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)

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 RATE OF CHARGE: Different principles 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.

2.

FIG NO 2 A. Notes on Discharge of Battery Set 1. 2. Monitor the discharge current for constant discharge of battery set. 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 d.

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:-

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 Reading of Battery charger ( TABLE NO 1 )
FLOAT MODE BOOST MODE FLOAT CUM BOOST MODE

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
CHARGER AC SUPPLY OFF CONDITION

i.

TERMINAL VOLTAGE READING +VE AND VE OF BATTERY SET ACROSS LOAD ACROSS TAPCELL

8. RECHARGING METHOD OF BATTERY SET Immediately after the discharge of the set, recharging should be followed. Whenever the manufacturers instructions are available for charging of the battery set, then the same may be followed. In absence of the manufacturers 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 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. 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 COMES TO 1200, THEN THOSE ARE REQUIRED TO BE CONDITIONED.

b)

TO ATTAIN THE REQUIRED SP.GRAVITY OF LOWER VALUE CELLS, INTERSAMPLING SHOULD BE DONE WITH CELLS OF HAVING HIGHER VALUE OF SP. GRAVITY.

9. MAINTENANCE GENERAL a. b. c. Keep the cell container, stand and surrounding dry and clean. Keep battery room well ventilated during charging the cells 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. 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. Keep battery room well lighted. Avoid direct sun light to the set Use battery grade distilled water (IS 1069) Never do the topping up of the cells by means of metal vessels. Keep the vent plugs and acid level indicating float plugs in position and tight.

i. j. k.

Never allow inflammable articles inside the battery room. Take particular care not to bridge the terminals with spanner while tightening the terminals. Always use gloves, while working with live battery.

MAINTENANCE SCHEDULE

$$ 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, and 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

d.

e. f. g. h.

CASE STUDIES ON D.C LEAKAGE IN A BATTERY CELL SYSTEM

Every battery system in Grid Sub-Station usually contains 110 cells of approx. 2 volt magnitude and total voltage of 220 V. So such system is called 220 Volt battery systems. To know the healthy ness of the battery voltage (total value) the terminals (load) of + Ve and Ve points are to be checked w.r.t an earth system. During this checking the following points are to be marked. 1. Ensure about the Earth connection in the system i.e. connection of Earthing to the mid cell (55th) point or Availability of lamp circuit with mid terminal earth. 2. Note; - If any one of the above is not available, then healthy ness of the battery set can not be checked. For such condition, voltmeter connected between +ve PERIODICITY ITEMS TO BE CHECKED terminal to earth or ve terminal to earth will not read 1. Measure and record the $$pilot any voltage. The theoretical analysis is described in DAILY cell Voltage, Sp. Gravity & the Theory A. (Use daily Electrolyte Temperature THEORY A record table) 2. Battery Voltage by Switching + VeA 1ST 55TH 110TH -Ve B off Charger L 3. Hourly reading DC Voltage, O Charger out put current and Trickle Charge Current A 1. Cleaning of terminals, topping D WEEKLY up distilled water if required V V 2. Review pilot cell reading and adjust the trickle charge current if required MONTHLY 1. Sp. Gravity, Voltage of each cell and electrolyte Temp. ( Table No 2 ) 2. Give Equalizing Charge 3. Switch off Charger and test tripping/ closing of any one feeder from Battery Source 4. Check all connection of battery and Charger 1. Allow Condition Charging

YEARLY

For this condition, circuit is not closed, because earth terminal acts as a floating point. So the voltmeter does not read any value for either terminals w.r.t. earth HEALTHY SYSTEM WITH EARTH FACILITY For this condition, with 55th cell being connected to earth causes reading of the voltmeter due to the closed path in the system. For healthy condition, voltmeter reading (+ve to Earth) and (-ve to Earth) becomes 110 volt.
L

O A D
V V

Trouble shooting Check from the glowing status of the bulbs used in the system
Sl. No 1 2 3 4 5 6 Glowing Status /Symptoms Equal glowing of both bulbs Both bulbs not glowing +ve side bulbs not glowing and Ve side bulbs glowing brighter +ve side bulbs glowing deem as compared to Ve side bulb. - ve side bulb not glowing and +Ve side bulbs glowing brighter - ve side bulb glowing deem as compared to +Ve side bulb. Remarks/ Check Healthy Condition Either one or both of the bulbs may be FUSED 2. If bulbs found OK, then wiring connected to the scheme may be disconnected any where. 1. +Ve terminal is solidly grounded or connected to ground with least resistance. ( Ref Analysis A ) 1. +Ve terminal is connected to ground with High resistance ( Ref Analysis B) 1. _-Ve terminal is solidly grounded or connected to ground with least resistance. ( self Explanatory ) 1. -Ve terminal is connected to ground with High resistance ( self Explanatory)

ANALYSIS A Consider the connection of lamps in the circuit being of rating 100 watts. Let the +ve terminal of the battery is connected to ground through resistance of less value (100 ohm for calculation). Now Resistance of the bulb = 2502 / 100 = 625 Ohm Equivalent Resistance between AB = (625 x 100) / (625+100) = 86 Ohm Now Voltage across AB

= (220 x86) / 86+625) = 20.6 Volt Voltage across bulb 2 = 20 26.6= 193.4V So, The second bulb glows brighter and +ve side doses glow very deem. Note :- For solid grounding the voltage becomes ZERO and total voltage becomes available across 2nd bulb only.

ANALYSIS - B Let the resistance connected of high ohmic value (2000 Ohm) for the Analysis B 10. BATTAERY SYMPOTOMS AND REMEDIES SYMPTOMS 1. Corrosion REMEDIES 1. Remove Electrolyte 2. Pour Distill Water 3. Refill with New Electrolyte

Equivalent Resistance between AB = (625 x 2000) / (625+2000) = 476.2 Ohm Now Voltage across AB = (220 x476.2) / 476.2+625) = 95.1 Volt Voltage across bulb 2 = 220 95.1= 124.9V So, the second bulb glows brighter and +ve side glows less bright.

SYMPTOMS 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 Direct discharge Expansion of plates 8.Reversal of negative plate It results due to connection of weak cell in the set, its discharge is ended before the other cells and causes the reversal of negative plate.

REMEDIES 1. Allow proper charging and discharging method 2. Contact manufacturer for replacement

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 Deterioratio n of Active material from +ve plate Temp. rise Bending of Plates 5.Under Charging Low sp. Gravity

2. Initial stage, repeat the low rate charging and Discharging. 3. 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. Allow proper charging and discharging method 2. Contact manufacturer for replacement Use correct electrolyte and charge the cell or replace with a good one.

9.Internal Discharger Local Action Gassing of the cells even under idle condition Abnormal gassing in charge condition Reduction of Battery capacity 10.Hardening of ve in Air Oxidation and heating in Air or exposed plates

Use correct electrolyte and charge the cell or replace with a good one.

1. Increase the Charging Rate to attain the sp. Gravity of 1200.

Pour distilled water and proper electrolyte and cover the plates

 Change of the colour of plate. Deterioratio n of Active material from +ve plate Bending of Plates

in proper manner

STANDARDS USED FOR BATTERY SL. 1 2 3 4 5 6 Standards IS-1885 IS-1652 IS-1069 IS-266 IS-8320 IEEE-450 Particulars Electrical vocabulary, Secondary Cells, Batteries Lead acid Batteries ( Plante ) Water for Storage Batteries Sulphuric Acid for Storage Batteries General Requirements for methods of Tests for Lead Acid Storage Batteries Maintenance , Testing and replacement of Large Acid Storage Batteries for Generating Station and SubStation Specification for rubber and plastic container for Lead acid storage Batteries Synthetic Separator for Lead acid batteries Part-2 latest revision High performance plante cell.

7 8 9

IEEE1146 IS-6071 BS-6290