Installation, Operation and Maintenance of Batteries

8/13/2019 Installation, Operation and Maintenance of Batteries

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110V 300AH BATTERY


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USB RECHARGE CELL


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FUEL CELL(Electricity not required to

charge)


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SIMPLE CONSTRUCTION OF FUELCELL


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WORKING PRINCIPLE OF FUEL CELL


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TYPE OF CHARGING

1.INITIAL CHARGING,2.TRICKLE CHARGING,3.BOOST CHARGING,4.QUARTLY EQUALISINGCHARGING,5.SPECIAL CHARGING.


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INITIAL CHARGING

Batteries received in dry state,Clean the outer surface of each cell,Clean the inside of the container withdry compressed air gently,Check for any crack or damage ,

CONT..


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Confirm the polarity of each cell , Arrange the cells with correctpolarity ,

Apply a thin layer of Vaseline aftercleaning of studs with sand paper,

Connect the cells with strapsproperly.

cont..


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Acid of 1190 sp.gr to be pouredslowly in all the cells with requiredlevel.Cells are to be allowed to absorbthe acid for more then12 to not

exceeding 24 hours cont..,


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Connect the battery set to chargerwith correct polarityKeep the variac in minimumpositionPrepare a log sheetSwitch on the charger and rise thecharger current by varying theposition of variac to the level asspecified by the manufacture or


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Normally the first charging current is 5%of capacity,Period of 1st charging is 100Hrs,For every 8 Hour Log reading of voltageand sp. gravity up to 90Hour,Temperature of the cell should notexceed 50 deg,

After 90 hrs equalize all cells by meansof adding acid or distilled water duringbalance 10 hrs period.STOP CHARGING.

Allow rest 12 to 24 hrs .


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First Discharge

Connect the load through a switch,ammeter and fuse unit,Load may be resistor bank, waterrheostat, lamp bank, heater etc,Discharging current may be adjustedaccording to the capacity of the

battery or stated by the manufacturer.


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Normally 10 hour rating of AH will bethe discharging current

For 300 AH Battery is 30ASp. Gr. and voltage readings to betaken every hour initially and every

15 minutes when battery voltagenearing 1.85 V * no. of cells(101.75Vfor 110V, 203.50 for 220V & 27.9 for30V Battery)


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When the voltage of the batteryreaches 1.85V * no. of cells thedischarging should be stopped If any cells Sp. Gr. reduced below1160 discharging should be

stoppedIf any cells voltage reduced below1.85V the discharging to be

stopped


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SECOND CHARGING

Restart the charging with fullcapacity of battery current,Log the reading ,Stop charging when threeconsecutive readings of Specific

gravity, Allow 12 to 24 hours rest,


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SECOND Discharge

Same procedure asfirst discharge cycle .


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THIRD CHARGING

Restart the charging with full capacityof battery current,Log the reading ,Stop charging when three consecutivereadings after reach rated values,

Now the battery ready foruse


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BATTERYMAINTENANCE


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Keep the battery Room clean & wellventilatedExhaust fan / fans always kept ONClean the battery and battery standregularlyClean the battery terminals and applypetroleum jelly when ever necessary

cont.


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Add distilled water to a requiredlevel,Take voltage, Sp.Gr. andtemperature of every cell weekly,

Analyze the readings and give

attention to the abnormality ifnoticed.


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Pilot Cell

Choose 3 cells as pilot cells,In every shift one of the pilot cellreading to be taken,

Pilot cell should be changed once in ayear, every month is preferable.Voltage, Sp.Gr. and temperature ofpilot cells to be analyzed regularly toascertain the performance of thebattery.


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Maintenance schedules as perCBIP PUBLICATION

Measurement of Sp.Gr. and cell voltage Monthly

Checking of electrolyte and topping up if necessaryMonthly

Checking of emergency DC lighting to control room

Monthly

Checking of earth fault Yearly

Checking of strap connection and applying of petroleum jellyYearly

Battery impedance test Yearly

Discharge test 3 years


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FLOAT Charging

After completion of charging cycle ifload is not connected - due tointernal resistance and surface

leakage, the battery will be drainedslowly. This should be compensatedby applying constant charging current

with specified value ,


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Trickle Charging

Due to internal resistance and surfaceleakage, the battery will be drainedslowly. +load current by the batterycharger . AGE charging current 1-2 yrs 1mA/cell 2- 4 2 4- 6 3 6- 8 4 8- 10 5


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ROUTINE CHARGING

The cells are to be charged atnormal rate. The cells areconsidered to be fully chargedwhen cells gas freely and the cellvoltage and sp. gravity reachnearer specific value. Thecharging current should bereduced to 50% of normal value.


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BOOST CHARGING

Required to restore the sp.gravity ofelectrolyte .


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Equalizing Charging

The trickle charging currentcould not be maintainedconstantly, hence due to low

charging current the batterywill discharge slowly. Tocompensate this discharge

equalizing charge should begiven every quarterly.cont,


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1.SP.Gravity falls below 5 points2.AH Discharge is more then 10% of

rated capacity3. Less then 1.85 V of any one cell

volt duration2.48 v 3to 8 Hrs2.39 v 4 to 12 Hrs

2.36 v 6 to 16 Hrs2.33 v 8 to 24 Hrs2.30 v 11 to 34 Hrs

2.27 v 16 to 48 Hrs


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Special Charging

If any major interruption to the stationi.e.

major tripping like Bus Bar protectionor LBB

tripping or interruption of stationsupply for a long duration or B/D ofcharger etc


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PROBLEM AND CAUSES

Buckling effect

This is due to too much chargingresulting in unequalexpansion of Positive plates.


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Sulfating


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Causes of SulfatingDuring this process, some of the sulphate

enlarge to the point where they can'taccept energy so they stay on the platein a very stable crystalline form. Over

time these sulphate crystals can build-upuntil efficiency is reduced and the batterydies. This process is the main reason forover 80% of all battery problems andfailures.


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SulphatingGood lead acid battery supposed to last 10years and more currently we only get 4 yearsout of it in the best case. In about 80% of the

cases the reason for decreased batteryperformance is a sulfate buildup on the plates.

This is due to too little charging. If the batteryis not sufficiently worked, abnormalsulphating results.

Symptoms of Sulphation


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Symptoms of Sulphation...

How can you tell if your battery is sufferingfrom excessive sulphation? Highertemperatures are observed during bothcharging and discharging (since a sulfatedbattery puts out a lower voltage, but powerrequirements remain the same so the current

increases).The net result is that running times of battery

powered equipment are shorter, electrolytespecific gravity decreases, output is reduced,and charge acceptance is slower and lessefficient.

Terminal corrosion also increases because thehigher operating temperatures increase water


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Hydration

Hydration is the action of water onthe lead plates. If a battery isexhausted to a point where theelectrolyte is practically water andcharging is not given at once, or Ifthe plates are not entirelyimmersed continuously in the

electrolyte.

Hydration will set up as a white

creamy substance .


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STRATIFICATIONIn this case a layer of strong acid lies at the

bottom of the cell for lack of circulation. Strongacid is liberated from the plates under theaction of the charging current and beingheavier than the weak electrolyte, falls bygravity to the bottom of the cell whereeventually a layer of acid with specific gravityas high as 1.4 may gradually buildup. It tends

to irregular working of plates. It could beovercome by circulation either through stirringup with a paddle or blowing up with an airpump.


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The VRLA Technology(Valve Regulated Lead Acid)

Evolution of battery design contd


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Evolution of battery design contd.

Closed Acid starved

Immobilized Acid

Vented

Less Top Acid

Free Acid

Conventional

VentedMore Top Acid

Free Acid

Low maintenance Valve regulated

Oxygen recombination principle


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Oxygen recombination principle

Oxygen Formed

during charge

Oxygen Combined

Indirectly with Hydrogen


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Special hybrid alloy utilized


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Special hybrid alloy utilized

Improved cycle life over lead antimony

Float characteristics of lead calcium

Excellent deep discharge recovery

Float current stable throughout life

Deep discharge cycle test


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Deep discharge cycle test


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ANY QUESTION

?


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Documents

Installation, Operation and Maintenance of Batteries