Commissioning of DC & UPS Systems

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Engineering Development Program (PEDP) of Engineering Services.

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Chapter : Electrical For additional information on this subject, contact
File Reference: EEX21106 W.A. Roussel on 874-1320
Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Directing the Start-Up and
Commissioning of DC/UPS Systems
Engineering Encyclopedia Electrical
Directing the Start-Up and Commissioning of DC/UPS Systems
CONTENTS PAGES
BATTERY SAFETY REQUIREMENTS: HAZARDS AND
PRECAUTIONS ..................................................................................................... 1
Building Support Systems ........................................................................... 1
Electrolyte ................................................................................................... 2
Hazards Present................................................................................ 2
Precautions for Reducing or for Eliminating Hazards ..................... 3
Electric Shock.............................................................................................. 4
Hazards Present................................................................................ 4
Hydrogen Gas.............................................................................................. 6
Hazards Present................................................................................ 7
BATTERY SYSTEM START-UP AND COMMISSIONING............................... 8
Pre-Startup and Commissioning Checks/Verification................................. 8
Initial Electrolyte Filling.............................................................................. 9
Initial Charging Procedures....................................................................... 13
Lead-Antimony Batteries............................................................... 13
Lead-Calcium Batteries.................................................................. 16
Cell Voltage and Specific Gravity Measurements..................................... 17
Cell Voltage ................................................................................... 17
Specific Gravity ............................................................................. 21
UPS SYSTEM START-UP AND COMMISSIONING........................................ 29
Verifying Proper Electrical Connections................................................... 29
Verifying Initial System Set-Up ................................................................ 30
Initial Conditions ........................................................................... 30
System Setpoints............................................................................ 31
Calibration Checks......................................................................... 35
Switching Functions ...................................................................... 35
Simulation of Line Power Source Loss ..................................................... 36
INTERPRETING START-UP AND COMMISSIONING TEST RESULTS....... 38
Battery System Start-Up and Commissioning........................................... 38
Battery Charger Start-Up and Commissioning.......................................... 41
UPS System Start-Up and Commissioning ............................................... 42
WORK AID 1: PROCEDURES AND CRITERIA FROM SADP-P-
103, IEEE 446, AND ESTABLISHED ENGINEERING
PRACTICES FOR INTERPRETING START-UP AND
COMMISSIONING TEST RESULTS........................................ 44
Procedure and Acceptable Values for Interpreting Start-Up and
Commissioning Data ................................................................................. 44
GLOSSARY ......................................................................................................... 58
Saudi Aramco DeskTop Standards 1
BATTERY SAFETY REQUIREMENTS: HAZARDS AND PRECAUTIONS
The Electrical Engineer must recognize the potential dangers and hazards that are associated
with batteries and battery systems. Through knowledge of the potential hazards, the Electrical
Engineer can adequately prepare the technicians to eliminate the source of a hazard or to
minimize the effects of a hazard. Failure to recognize or consider the areas of potential
hazards could result in equipment damage or in injury to personnel. The following topics that
are pertinent to potential hazards are discussed in this section:
Building Support Systems
Electrolyte
Electric Shock
Hydrogen Gas
Building Support Systems
The hazards when working with secondary batteries are increased when building support
systems are non-existent or are inoperable. One responsibility of the start-up engineer is to
verify the existence of these systems and their functional operation prior to initiating start-up
procedures on the battery and UPS systems.
The building support systems and the verifications that are required for each system are as
follows:
For battery rooms that use pressurized air systems, verify that the monitoring
system actuates the local alarm on a loss of room pressurization.
For battery rooms that use air exhaust systems, verify that the area exhaust fan
operates.
Verify that the battery room/UPS room is air conditioned to 25
o
C. If the
battery room temperature is below 25
o
C, cell capacity is reduced. If the battery
room temperature is consistently higher than 29
o
C, cell life is shortened .
Verify that eyewash facilities (portable or permanent) are installed and
operable. (Eyewash facilities are not required for sealed battery installations.)
Verify that floor drains are functional.
Verify that portable water facilities are available for cleanup and flushing of
electrolyte spills.
Verify that the following safety items and test equipment are installed or are
available for immediate use:
- Chemical worker's goggles.
- Face shield.
- Apron.
- Acid/alkaline resistant gloves.
- A supply of bicarbonate of soda to neutralize sulfuric acid.
- A supply of citric acid to neutralize potassium hydroxide (nickel-
cadmium battery rooms).
- Cell lifting straps and strap spreaders.
- Thermometer to measure electrolyte temperature.
- Hydrometer with temperature correcting scale to measure electrolyte
specific gravity.
Electrolyte
Because of the abundance of electrolyte in large storage batteries, and because of the
frequency with which electrolyte is handled, electrolyte is one of the major hazards that is
associated with batteries. The Electrical Engineer must be familiar with the hazards that are
associated with electrolytes and with the precautions to be taken to minimize these hazards.
Hazards Present
Electrolyte presents a hazard to equipment and personnel because of the electrolyte's acidic
and alkaline properties. If electrolyte is improperly handled, the electrolyte will cause
damage to the battery and to the battery rack, or it will cause injury to personnel.
The hazard for equipment occurs from electrolyte that is spilled or dropped onto the
equipment. Electrolyte is most likely to be spilled on the battery or on adjacent equipment
during the initial battery fill and during the periodic electrolyte testing. If the spilled
electrolyte is not properly neutralized and removed, the following problems could occur:
The affected equipment will corrode and deteriorate over time.
The electrolyte will contaminate the battery casing and will cause battery
grounds.
In installations that use wood support channels, excessive electrolyte that is
absorbed into the wood can result in cell discharge through the saturated wood.
The electrolyte that is spilled on the battery connections could impair electrical
current flow.
Personal hazards from electrolyte occur as a result of direct contact with electrolyte. The
electrolyte that is used in the battery, sulfuric acid (acidic), or potassium hydroxide (alkaline),
can cause skin burns, eye injuries, and clothing damage. Direct contact with the electrolyte
can occur while the battery is being initially filled, during the periodic electrolyte testing, or
as a result of casual contact with spilled electrolyte. Electrolyte that is spilled on the floor
also produces slippery conditions that could be hazardous to personnel.
Precautions for Reducing or for Eliminating Hazards
The Electrical Engineer must be aware of the precautions that should be taken to reduce or to
eliminate the hazards that are associated with battery electrolytes. The majority of the hazards
to personnel and equipment occur from handling of the electrolyte during the filling and/or
testing process. The use of common sense and good housekeeping practices will reduce or
eliminate most of the hazards. The following guidelines will minimize the potential hazards
that battery electrolytes present:
All spills from the battery equipment should be rinsed away, and the spill area
should be neutralized. After neutralization of the spill area, a final rinse should
be performed through use of potable water.
A bicarbonate of soda solution (100 grams per liter of potable water) should be
used to neutralize sulfuric acid.
A citric acid solution (90 grams per liter of potable water) should be used to
neutralize potassium hydroxide.
When working with electrolyte, personnel are to wear protective clothing,
which is provided as part of the battery room safety equipment.
Extreme care should be used in the removal of a cell vent cap or an arc
suppressor. In the unlikely event of cell pressurization, such a removal could
result in the release of electrolyte.
Only battery handling straps and strap spreaders that are approved by the
manufacturer should be used to transport or to physically handle the battery
cells.
When hydrometer tests are performed, the electrolyte should be removed with
care to avoid unnecessary splashes and spills.
To avoid overfill and splashes, electrolyte should be added to battery cells
through use of proper cell electrolyte filling equipment.
Electric Shock
All personnel who work on or near batteries must remember that the possibility of electric
shock exists at all times. The following topics that are pertinent to electrical shock are
discussed in this section:
Hazards Present
Hazards Present
Charged batteries that are connected in large series strings have the ability to deliver high
short circuit currents. Because the short circuit current capability of these cells (batteries) can
reach many thousands of amperes, the exposed conductors of a charged battery should be
treated with respect and caution. Severe burns can result if metallic objects (such as jewelry
and hand tools) make contact between two opposing cell terminals.
Electrical shock hazards always exist with any series string of batteries. The shock hazard
that batteries present is best illustrated through application of Ohm's Law (E = IR). For
example, the resistance of damp skin can be as low as 300_, and the amount of current flow
that normally is considered lethal is 0.1A. As Ohm's Law shows, a 30V (300_ X 0.1A = 30V)
series string of batteries could produce a lethal shock.
Electric shock hazards normally are only associated with large, high voltage battery
installations; however, even smaller batteries, such as those found in communications
equipment, forklifts, and automobiles, can pose an electric shock hazard. The most common
causes of electric shock from a battery are simultaneous contact of the positive and negative
terminals (by shorting out the positive and negative terminals with an uninsulated tool) or
contact of a cell terminal with the common system ground. In addition to the electrical shock
hazard, shorting the positive and negative terminals can damage the battery.
Electrical shock hazards also can exist when the battery casing or the battery rack is touched.
This hazard can exist because of dirty battery casings and electrolyte spills. The electrolyte
spills and the dirt can cause a low resistance current path from the battery terminal to the
battery casing. In this situation, a shock hazard will exist if contact is made between the
battery case and system ground.
To reduce or eliminate electrical shock hazards, all personnel who work on or near batteries
must be fully aware of hazards that are associated with batteries and the affects of electrical
shock. The precautions for the reduction or the elimination of hazards of electrical shock in a
battery room are the same as the precautions for all electrical systems. Common sense should
prevail in instances that concern electrical equipment maintenance. Also, the following
guidelines should be observed:
Electrical safety gloves should be worn for work with the battery cables and the
battery connections.
Electrical safety goggles should be worn to protect against possible flashburns
that are caused by short circuits.
Electrical safety mats should be used to cover all exposed electrical parts in the
work vicinity.
All metal articles such as watches, rings, necklaces, and belt buckles should be
removed from the body and from the clothing.
All tools should be insulated so that no more than three inches of exposed
metal exists.
All tools should be properly secured during maintenance and should not be left
unattended on the tops of the battery cells.
All electrolyte spills should be immediately cleaned up, neutralized, and
washed down.
In case of an emergency, maintenance personnel should be qualified to perform
first aid and cardiopulmonary resuscitation (CPR).
Hydrogen Gas
The potential hazards that are presented by hydrogen gas are most prevalent during charge
and discharge operations in the battery room. This section will cover the following topics that
are pertinent to hydrogen gas:
Hazards Present
Hazards Present
The greatest hazard that is associated with hydrogen (H
2
) gas is a gas explosion. Under
normal operating conditions, hydrogen accumulation in the battery room is not substantial and
is not a major concern; however, during a battery charge, the battery-charging current
generates H
2
gas at a rate that can produce explosive hydrogen-air mixtures. Hydrogen
concentrations become flammable when the concentration in air is between 4% and 79% of
the total battery room air volume. The hydrogen-gas air mixture is considered explosive
when the hydrogen that is in the air exceeds 4% by volume. This 4% quantity is the Lower
Explosive Limit (LEL) value. A properly designed ventilation system will provide a
sufficient number of air changes per hour to keep the hydrogen concentration below 2% of
the total volume of the battery room.
In addition to the release of hydrogen gas, some batteries may release small quantities of toxic
gases, such as stibine and arsine. Stibine and arsine are formed when the metals antimony
and arsenic come in contact with hydrogen during a battery overcharge condition. Antimony
and arsenic are commonly used in lead-acid batteries to strengthen the plate material and to
reduce plate corrosion. Although the conditions that produce these toxic gases are rare, the
Electrical Engineer must be aware that these conditions do exist. Because these gases are not
monitored, maintenance of proper ventilation of the battery room is imperative.
Good engineering design practices indicate that the ventilation that is required to maintain
hydrogen concentrations below the 20% LEL (approximately 1% hydrogen) also will keep
stibine and arsine below their toxic limits; therefore, if the ventilation system is correctly sized
to prevent a hydrogen explosion, the threat of toxic poisoning from stibine and arsine is also
eliminated.
Hydrogen fires and explosions can be prevented through adequate battery room ventilation
and through minimization of ignition sources. Hydrogen buildup is prevented by a well
ventilated battery room. Ignition sources (such as smoking, open flames, and maintenance
functions) that are capable of producing an open arc must be eliminated.
A defective battery charger can cause excess hydrogen levels. If the charger malfunctions,
excessively high battery charge rate can result. These high charge rates can produce
substantial volumes of hydrogen. Adequate, periodic maintenance testing of the battery
charger will reduce the possibility of such an overcharge condition.
BATTERY SYSTEM START-UP AND COMMISSIONING
This section of the Module will discuss the following topics that are pertinent to battery
system start-up and commissioning:
Pre-Startup and Commissioning Checks/Verification
Initial Electrolyte Filling
Initial Charging Procedures
Cell Voltage and Specific Gravity Measurements
Pre-Startup and Commissioning Checks/Verification
Before the actual battery start-up and commissioning can begin, the Electrical Engineer must
inspect the battery equipment for proper installation, acceptable equipment conditions, and
security of electrical connections. The following items are to be checked and/or verified:
Verify that the battery frame is assembled in accordance with the
manufacturer's recommendations and that the battery frame is securely
anchored to the floor.
Check for any nicks or chips in the battery rack acid-proof paint. Any chips or
nicks must be covered with touch-up paint that is provided by the battery rack
manufacturer. If nicks or chips are not touched-up, and if corrosive electrolyte
is spilled on the rack, the electrolyte will attack the exposed steel. Such attacks
eventually can result in a structural failure of the battery rack and a possible
battery rack collapse.
Verify that the cells rest on plastic or wood support channels. These channels
electrically insulate the cell from the steel frame.
Inspect cells for electrolyte leakage that can occur as a result of a cracked jar or
a broken seal. All damaged cells must be replaced.
Check the color change temperature sticker that is applied to the exterior of
each cell to determine whether the cell temperature has exceeded 45
o
C. If
color changes are observed, the affected cells must be replaced.
Verify that the flame arrestor or the explosion-resistant vent caps, which collect
electrolyte spray and return it to the cell, are intact and are properly installed.
Check each connection for the correct complement of fastening hardware. Any
connections that do not comply with the manufacturer's installation instructions
must be corrected.
Apply the correct torque to each battery connection through use of a torque
wrench. The torque values must be in accordance with the manufacturer's
recommendations.
Verify that all terminal connector bolts, nuts, and washers have been coated
with an anti-oxidant.
Use the manufacturer's test instructions to collect the field data that establishes
the initial connection resistance values of each battery post connection. These
baseline resistance values will be used as comparison data for future
maintenance procedures. The Individual Cell Terminal Resistance Record is
included in Work Aid 1.
At the completion of the intercell connections, a voltmeter should be used to
check the polarity of the series connections. The total voltage of the series
string should read approximately twice the number of cells (e.g., 2 x 60 cells =
120 volts). If the voltage is too low, one or more cells may be improperly
connected. The battery string should be immediately inspected, and the faulty
connection should be corrected.
Initial Electrolyte Filling
Cells that are received from the manufacturer already may be filled with electrolyte, or they
may be in a dry charge state. The size and the weight of the cell usually determines the
method of shipment. If the received cells are filled with electrolyte, the technicians only need
to verify the electrolyte level and to measure the specific gravity of the electrolyte prior to the
application of the initial (freshening) charge. If the cells are shipped dry charged, the
Electrical Engineer must direct the initial electrolyte filling process and ensure that the proper
electrolyte is used. If the battery will not be placed in operation immediately after installation,
the initial filling should be delayed because dry batteries can be stored for longer periods of
time than can wet batteries.
Before cells that are received in a dry-charged state are filled, a verification must be
performed to ensure that the cells are sealed and that the moisture vent cap is in place. A
missing or a broken vent cap could indicate that the cell is contaminated.
Each cell is to be filled to the correct level prior to the application of the freshening charge.
The cells are to be filled with the correct electrolyte as directed by the cell manufacturer.
Lead-acid cells use an electrolyte that consists of sulfuric acid and demineralized water;
nickel-cadmium cells use an electrolyte that consists of potassium hydroxide and
demineralized water. Concentration levels are dictated by the cell manufacturer.
The use of demineralized or deionized water is essential to the chemical reaction within the
cell. Demineralized water is to be used in order to prevent the formation of foreign mineral
deposits on the cell plates. Such deposits contaminate the cell and shorten the life of the cell.
The demineralized water is to be tested to ensure that the impurity levels do not exceed the
following specifications:
The water must be free from suspended matter and must be colorless when
viewed through a depth of 300 mm (12 in).
The total solids in the water must not exceed 20 parts per million (ppm).
The chloride level must not exceed 20 ppm.
Concentration levels of the following impurities must not exceed the levels that
are shown:
- Iron 10 ppm
- Copper 5 ppm
- Manganese 0.1 ppm
- Lead 2.5 ppm
- Calcium 10 ppm
- Magnesium 10 ppm
- Zinc 2.5 ppm
To support the required chemical reactions of a battery, the diluted solutions of sulfuric acid
and demineralized water or potassium hydroxide and demineralized water must be accurately
measured to produce the proper mix of electrolyte. The concentration of acid in the
electrolyte is determined through measurement of the specific gravity. The specific gravity of
an electrolyte is the measure of the density of the electrolyte as compared to the density of
demineralized water. For example, the specific gravity of demineralized water is 1.000, and
the specific gravity of sulfuric acid is 1.835. Sulfuric acid, therefore, is 1.835 times denser
(heavier) than demineralized water. To obtain the proper electrolyte concentration, various
amounts of demineralized water (specific gravity 1.000) and sulfuric acid (specific gravity
1.835) are mixed. Dependent on the percentage of demineralized water and acid that is used,
the resultant specific gravity of the diluted sulfuric acid will be between 1.000 and 1.835.
Figure 1 shows the specific gravity of an electrolyte for various amounts of demineralized
water and sulfuric acid. The figure illustrates that the specific gravity is lower for a higher
volume of water in the electrolyte. The figure also shows that specific gravity for a smaller
amount of water is much higher.
The same relationship is shown with the percentage curve. As the percentage of acid in the
solution increases, the specific gravity of the solution also increases. The exact specific
gravity that is required for a given cell will be specified by the manufacturer. The specific
gravity for a lead-acid battery is usually controlled in the range of 1.215 and 1.250.
Sulfuric Acid - Water Concentrations
Figure 1
Extreme caution must be taken when the acid and demineralized water are mixed. The acid
and demineralized water should be mixed before they are added to the battery cells to ensure
proper mixing of the electrolyte. Proper mixing of the acid and demineralized water will
minimize stratification of the acid that could damage the plates of the cell. The following
guidelines should be followed when electrolyte is mixed:
Personal protective equipment should be worn.
Eyewash stations should be readily available.
Extra water supplies should be available in case of an electrolyte spill.
The acid and demineralized water should be mixed in a properly ventilated
area.
When electrolyte is prepared for lead-acid batteries, the sulfuric acid must be
introduced into the water.
WARNING: Reversal of the mixing technique (e.g., introduction of water into
sulfuric acid will result in a violent reaction that causes acid and water to splash
from the mixing container.
The acid should be "flowed" at a very slow pace and in small increments to
allow time for the release of heat that is produced during the mixing procedure,
which reduces the possibility of splashing.
For potassium hydroxide solutions, the potassium hydroxide flakes or pellets
should be carefully and slowly added to the demineralized water. Due to the
excessive amounts of heat that are produced while potassium hydroxide is
being mixed, field mixing is not recommended. The use of premixed solutions
is recommended.
After the proper type of electrolyte has been selected and mixed, the electrolyte can be added
to the cells. All of the electrolyte safety precautions should be followed while the cells are
filled. Each cell should initially be filled to the lower fill line because the electrolyte level
will vary with the electrolyte temperature. The cell should be allowed to set for several hours
(as recommended by the manufacturer) after the initial filling to allow time for the plates to
soak. The soak time allows the plates to absorb electrolyte and allows the temperature of the
electrolyte to stabilize.
After the soak time has elapsed, the temperature of the electrolyte should be checked.
Because the expansion and contraction characteristics of the electrolyte largely depend on cell
design and on electrolyte volume, the Electrical Engineer must refer to the manufacturer's
specifications to ensure that the electrolyte is in the proper range. For example, a storage
battery design may result in an electrolyte level charge of 1/8 of an inch for every one degree
change in electrolyte temperature. Therefore, if the temperature of the electrolyte during the
initial fill is 15
o
C, and if the ambient temperature of the battery room is 20
o
C, the electrolyte
level would be expected to rise 5/8 of an inch. This level rise would equate to 1/8 of an inch
for each one degree change in temperature. The electrolyte level should be adjusted so that
the level is in the normal operational range when the electrolyte reaches normal operating
temperature. The operational range is indicated on the cell with upper and lower fill lines.
This operational range is provided to allow for the expansion and contraction of the
electrolyte.
Initial Charging Procedures
Initial charges are performed on batteries that have been shipped wet or that have been filled
in the field. Wet cells typically are shipped in a fully charged state; however, the cells may
loose some of their charge during shipping, handling, and installation. The initial charging
procedure (freshening charge) is performed to bring the cell up to its fully charged state. Wet
cells that are not immediately placed in service are to be periodically monitored to verify the
cell's state-of-charge. Measurement of the cell's state-of-charge is accomplished through
measurement of the specific gravity. A freshening charge must be applied to batteries that
experience a 25 point (0.025) decrease in specific gravity. Wet cells that are not placed in
service by the installation date that is recommended by the battery manufacturer also will
need to undergo a periodic freshening charge.
Cell manufacturers recommend shelf storage durations. These shelf periods vary by the type
of cell and the electrolyte status (e.g., wet or dry charged). Cells that are received wet or cells
that are made wet in the field may be stored; however, all wet cells must receive periodic
charges while they are in storage. Cells that are filled with electrolyte should not be stored for
long periods in an uncharged condition. The uncharged period varies between cell types.
Stored lead-antimony cells require a periodic charge every three months; stored lead-calcium
cells require a freshening charge every six months.
The initial charging procedures will vary dependent upon the type of battery cells. The initial
charging procedures for the following types of batteries are discussed in this section:
Lead-Antimony Batteries
Lead-Calcium Batteries
Lead-Antimony Batteries
Lead-antimony batteries must receive an initial charge within three months of the date of
shipment from the manufacturer. This initial charge is called a freshening charge, a boost
charge, or a forming charge, and it is typically applied by the constant potential charge
method. The constant potential charge method is performed through application of a constant
voltage to the battery terminals for the period of time that is specified by the manufacturer.
Figure 2 shows the voltage and the current characteristics of a cell during a constant potential
charge. Graph (a) of Figure 2 shows the steady output of the battery charger for the duration
of the charge. Graph (b) of Figure 2 shows the battery cell voltage and the battery charge
current for the duration of the battery charge. As shown in graph (b) of Figure 2, the cell
voltage quickly rises to the charger output voltage when the charge is started. The battery
charging current drops close to zero as the charge progresses. The freshening charge should
continue at the manufacturer's specified voltage, which usually is the equalize voltage, for the
period of time that is specified by the manufacturer to ensure that the battery cells are placed
in a fully charged condition. The value of voltage that is applied to the cells and the length of
time that the voltage is applied varies from cell to cell and from manufacturer to
manufacturer.
Constant Potential Charge
Figure 2
Figure 3 shows the typical initial charge volts per cell and the charging time periods for a
lead-antimony battery that has a nominal specific gravity of 1.215. The initial charge volts
per cell (VPC) value that should be used for the initial charge can be calculated through
division of the total system voltage by the number of cells that are in series. The total system
voltage is the maximum voltage that the connected equipment will tolerate or the maximum
voltage output capability of the battery charger, whichever value is less. The calculated initial
charge VPC then is applied by the charger for the specified period of time (minimum hours)
that is shown in Figure 3.
During the initial charge, a pilot cell should be monitored to ensure that the battery electrolyte
temperature does not rise above 49
o
C. If the pilot cell electrolyte temperature reaches 49
o
C,
the charge must be stopped, and the batteries should be allowed to cool on open circuit. The
battery charge should not be restarted until the pilot cell electrolyte temperature has lowered
below 32
o
C.
Initial Charge Volts Per Cell
(VPC)
Minimum Hours for Nominal
Specific Gravity of 1.215
2.39
2.36
2.33
2.30
2.24
40
60
110
168
210
Typical Initial Charge Values for a Lead-Antimony Battery
Figure 3
Lead-Calcium Batteries
Lead-calcium cells must receive an initial charge within six months of the date of shipment
from the manufacturer. The initial charge of the lead-calcium cell can be delayed longer than
the lead-antimony cell because the lead-calcium cell has a lower self-discharge rate and,
therefore, will maintain its charged state for a longer period of time.
The initial charge for a lead-calcium battery should be performed through application of an
initial charge volts per cell (VPC) that corresponds to the nominal specific gravity of the
battery. The battery manufacturer normally specifies a minimum acceptable initial charge
VPC and a nominal initial charge VPC. The initial charge can be performed at any voltage
that is within the specified range, but the preferred initial charge VPC is the nominal initial
charge VPC. The output capabilities of the battery charger or the maximum voltage that can
be applied to the connected load may prevent performance of the initial charge at the nominal
initial charge VPC. Figure 4 shows the initial charge VPC values that correspond to typical
lead-calcium battery nominal specific gravities.
The duration of the initial charge for a lead-calcium battery is not fixed. The charge is
continued until the lowest individual cell voltage value ceases to rise. After the lowest
individual cell voltage ceases to rise, the charge is maintained for an additional 24 hours.
During the initial charge, the individual cell voltage values must be monitored to determine
when the lowest individual cell voltage ceases to rise. Also, the temperature of the pilot cells
must be monitored to ensure that the electrolyte temperature does not exceed the values that
were previously stated for lead-antimony batteries.
Nominal Specific Gravity Initial Charge VPC
Minimum Acceptable Nominal
1.170
1.210
1.225
1.250
1.275
1.300
2.10
2.13
2.15
2.18
2.20
2.23
2.29
2.33
2.36
2.38
2.40
2.45
Initial Charge VPC Values for Lead-Calcium Batteries
Figure 4
Cell Voltage and Specific Gravity Measurements
Cell voltage and specific gravity measurements are performed on each cell to ensure that each
cell operates at the optimum condition. Measurement of cell voltage and specific gravity will
provide an evaluation of the static charge, which provides an indication of the cell
electro/chemical condition and battery cell capacity. The following topics will be discussed in
greater detail:
Cell Voltage
Specific Gravity
Cell Voltage
Cell voltage is the electrical potential that is measured between the positive and negative
terminals. Cell voltage is measured during an open circuit (no load) condition. The recorded
voltage will be a true indication of the cell's standard potential or theoretical voltage and,
when plotted on an X-Y axis graph, can be used to predict remaining battery capacity.
Theoretical voltage or standard potential is calculated from the electrode potentials (e.g.,
oxidation potential of the anode and reduction potential of the cathode). Theoretical cell
voltage is a function of the anode and cathode materials, the composition of the electrolyte,
and the electrolyte temperature. With the cell temperature at the normal value of 25
o
C, and
with the specific gravity in the normal operating range, the measured cell voltage at open
circuit is a close approximation of the theoretical voltage.
The open circuit voltage of a cell depends on the state of the static charge. Figure 5 shows a
typical cell voltage curve. The curve is a plot of open-circuit voltage vs. percent of rated
capacity. If the cell has not been charged or discharged within 24 hours, the curve is accurate
to within 20%. If the cell has not been used for five days, the curve is accurate to within 5%.
The measurement of the open-circuit voltage to determine the state of charge is based on the
relationship between the electromotive force (open-circuit voltage) and the concentration of
the electrolyte in the battery. Electrolyte concentration level is determined through
measurement of the cell specific gravity.
Open-Circuit Voltage vs. State of Charge
Figure 5
Ideally, the voltage of a new battery cell on open-circuit will approach the theoretical standard
potential. Over a period of time, the electrolyte in the battery can become contaminated, and
the battery plates will corrode and deteriorate. As a result, the cell's voltage will drop. In
some instances, the contamination can be corrected through application of one or more
equalizing charges that are followed by deep discharged cycles. If the charge/discharge
cycles are successful, the battery cell's voltage will rise and approach the voltage of a new
cell. If the charge/discharge cycles have no affect, as determined by an ever decreasing cell
voltage, the cell must be replaced.
Individual cell voltage readings are obtained through connection of a voltmeter across the
positive and negative terminals of the cell. This measurement can be obtained through use of
a portable voltmeter or can be observed at a permanently installed individual cell voltage
(ICV) meter panel. Panelmeters provide a convenient way to check the individual cell
voltages; however, because panelmeters reflect voltage losses that result from the meter leads
(interconnecting wires), mechanical connections, selector switch, and the meter, panelmeters
do not provide the most accurate indication of cell voltage. If the cell voltage that is indicated
at the panelmeter appears questionable, a calibrated portable voltmeter should be used to
verify the voltage of the cell that is in question.
Each battery has several individual cell voltage ratings. These ratings reflect the electrical
condition of the cell or battery and represent the voltage condition from fully charged to
discharged. The individual cell voltages of a battery will vary with the operating
environment, the state of the charge, and the type of cell composition. The following is a list
of the individual cell voltage ratings for a typical lead-acid and nickel cadmium battery:
Individual Cell Voltage Lead-Acid Nickel Cadmium
Open-Circuit Voltage 2.1 1.29
Nominal Voltage 2.0 1.2
Working Voltage 2.0-1.8 1.25-1.10
End Voltage 1.75 1.10
The open-circuit voltage is the difference in potential between the terminals of the battery cell
when the battery circuit is open or at a no-load condition. The open-circuit voltage is the
voltage that is closest to the theoretical or standard potential of a battery cell. The nominal
voltage of a battery cell is defined as the characteristic operating voltage or the rated voltage
of the cell. The nominal voltage is the value that is used to determine the total voltage of the
battery (number of battery cells multiplied by the nominal voltage). The working voltage is
the voltage that is representative of the actual operating voltage of the cell under load. The
end voltage is defined as a point along the discharge curve below which no usable energy can
be drawn for the specified application. The battery cell is then considered completely
discharged.
Through close monitoring of a battery's individual cell voltage during operation and charging,
the Electrical Engineer can determine the general condition of any cell in the battery. Figure 6
shows a typical cell voltage curve during a battery discharge and charge cycle.
Figure 6 also plots individual cell voltage over time for a battery discharge (time 0 to time 1)
and a battery charge (time 1 to time 2).
Typical Discharge/Charge Curve of a Lead-Acid Cell
Figure 6
At time 0, the cell voltage is at the nominal value, 2.00 volts. As the battery discharges from
time 0 to time 1, the cell voltage drops to its end voltage of approximately 1.75 volts. At time
1, a battery charge is started and the cell voltage quickly rises above the nominal voltage
value. The cell voltage will continue to increase until the charge is complete (time 2). When
the charge voltage is removed, the individual cell voltage will decrease to the nominal value.
If an individual cell voltage fails to respond in a similar manner, the cell is probably defective
and should be removed from the battery for further maintenance evaluation.
Specific Gravity
The specific gravity is a measure of the density of an electrolyte in comparison to the density
of pure water. The specific gravity of the electrolyte will vary with the state of charge as a
result of the chemical reactions that occur within the cell. This section will discuss specific
gravity as it relates to a lead-acid cell.
During battery discharge, the density or weight of the electrolyte will decrease because of the
disassociation of the sulfuric acid molecules; therefore, with less sulfuric acid in the battery
cells, the specific gravity of the electrolyte will decrease. During a battery charge, the sulfuric
acid is recombined to increase the specific gravity.
Figure 7 shows the specific gravity of a battery for a cell discharge and a cell charge. The
specific gravity plot overlaps the cell voltage plot that was previously described in Figure 6.
Although no values are shown for specific gravity, the graph shows the relationship of the
specific gravity to the volts per cell during a discharge/charge cycle. From time 0 to time 1, a
constant cell discharge rate will result in a linear decrease in the specific gravity. During the
charge cycle from time 1 to time 2, the specific gravity will rise to the nominal value, but the
rise is not linear. A rapid excursion of specific gravity occurs when the cell voltage (volts per
cell) rises above 2.4 volts and cell gassing occurs. Cell gassing causes turbulent electrolyte
mixing, which causes the rapid rise in specific gravity. The state of charge of the cell can be
determined through use of the specific gravity plot and is considered to be the most reliable
indicator of the cell's state of charge.
Typical Voltage and Specific Gravity Characteristics of a Lead-Acid Cell
Figure 7
The specific gravity of the electrolyte is measured with a hydrometer. The most common
type of hydrometer is the syringe type, as shown in Figure 8, view A. The hydrometer
consists of a sample holding glass tube, a rubber bulb, and a float. The float is specially
designed and calibrated to read the specific gravity of a solution when it is immersed in the
solution. The hydrometer float consists of a hollow glass tube with a calibrated scale axially
imprinted along the stem of the tube. The tube is weighted at one end and is sealed at both
ends. Because each hydrometer float is calibrated for a specific range of specific gravities,
accurate measurements of specific gravity only can be obtained through use of the correct
float.
Typical Hydrometer
Figure 8
To measure the specific gravity of a battery cell, electrolyte is drawn into the hydrometer
holding glass tube in a sufficient quantity to cause the float to enter into suspension. Once the
float is in suspension, the scale of the float is read at the meniscus interface of the float and
the electrolyte. Typical examples of hydrometer readings also are shown in Figure 8.
The example in view (B) shows that the float has sunk low in the electrolyte; the example in
view (C) shows that the float is at a higher level in the solution. The float height difference
between the two examples is due to the difference in the specific gravities of the sample
electrolytes.
The specific gravity of the solution is directly read from the calibrated scale, as indicated by
the meniscus of the solution. For example, the hydrometer in view (B) indicates a specific
gravity of 1150, and the hydrometer in view (C) indicates a specific gravity of 1270. The
specific gravity readings of 1150 and 1270 are equivalent to 1.150 and 1.270 respectively but
commonly are referred to as eleven-fifty and twelve-seventy.
The following guidelines must be followed to obtain an accurate specific gravity
measurement through use of a typical hydrometer:
The interior of the hydrometer glass sample tube and the surface of the float
must be clean. Dirty floats cause incorrect measurements, and dirty sample
tubes can obscure the float scale. To avoid these conditions, the hydrometer
should be periodically inspected and, if necessary, cleaned with a mild soap
solution. All washed components should be rinsed with demineralized water
before the components are re-assembled.
Before the electrolyte sample that is to be read is drawn into the hydrometer,
the electrolyte should be drawn into the hydrometer and then discharged into
the cell two to three times to obtain a representative sample.
Sufficient electrolyte must be drawn into the hydrometer in order to cause the
calibrated tube to float in the electrolyte. The float must not touch the top or
the bottom of the sample tube and it must remain relatively free of the sample
tube sides.
Specific gravity readings should be obtained before water is added to the cell.
If water has been added, the hydrometer readings should be delayed until
completion of an equalizing charge or until the electrolyte has had an
opportunity to mix for at least one hour.
The meniscus/scale interface should be held at eye level in order to prevent
reading the float scale in parallax.
At the completion of the measurement, all of the electrolyte should be returned
to the cell from which it was removed.
Before the hydrometer is placed in storage, it should be flushed with
demineralized water.
Because the measured value of specific gravity changes as the temperature and the level of
the electrolyte changes, the measured values must be corrected to obtain the actual values.
Figure 9 illustrates the change in the measured value of specific gravity with a change in cell
electrolyte temperature.
Specific Gravity vs. Temperature
Figure 9
As the temperature of the electrolyte increases, the following changes occur to the electrolyte:
The density of the electrolyte decreases, as measured by the hydrometer.
The volume of electrolyte increases (i.e., the level of electrolyte increases).
The ratio of the weight of acid to the weight of water for a specific volume
decreases; therefore, the measured specific gravity decreases.
Conversely, as the electrolyte temperature decreases, the measured specific gravity increases.
Because the temperature only affects the value of specific gravity that is measured by the
hydrometer and not the actual value of available acid, the measured value must be corrected.
This compensation correction will adjust all specific gravity readings to a standard
temperature (25
o
C). Adjustment of the readings for the temperature will provide accurate
specific gravity readings. These readings will then permit accurate comparisons between
cells.
The following guidelines are used to adjust the specific gravity readings to a standard
temperature of 25
o
C:
Add one point (.001) to the specific gravity reading for every 1.67
o
C that the
electrolyte temperature is above the 25
o
C standard.
Subtract one point (.001) from the specific gravity reading for every 1.67
o
C
that the electrolyte temperature is below the 25
o
C standard.
A change in electrolyte level also will affect the measured value of specific gravity. This
change is due to the change in concentration of the acid and the water in the electrolyte.
Electrolyte levels can change for the following reasons:
Evaporation
Leakage
Spillage of electrolyte during sampling
Extreme temperature changes
Addition of water to the cell
The actual change in specific gravity that occurs as a result of electrolyte level changes will
vary with the size of the battery and the electrolyte concentrations. In some installations, a
change in level can have a negligible effect on the specific gravity as long as the electrolyte
remains in the normal range. In other installations, the change in electrolyte level can be
significant. The manufacturer's technical literature must be consulted to obtain the electrolyte
level correction factor for each particular battery.
The expected specific gravity readings of a cell will depend on the type of cell, the type of
electrolyte, and the state of charge of the cell. Typical specific gravity readings for a lead-
acid and a nickel-cadmium cell are provided in Figure 10.
The readings reflect various states of charge that range from a fully discharged battery to a
fully charged battery. The values that are provided in Figure 10 are representative of the
values that would be measured during a battery discharge at a constant discharge rate. A
battery that is being charged or that is being heavily discharged will not produce accurate
specific gravity readings. As previously shown in Figure 7, the specific gravity will linearly
decrease during a battery discharge; however, during a charge, the specific gravity rises in a
non-linear fashion.
Typical Specific Gravity Readings
Figure 10
UPS SYSTEM START-UP AND COMMISSIONING
The start-up and commissioning procedure of a UPS system consists of a series of system
checks and tests that are performed in coordination with the manufacturer. The testing
methods and the procedural steps to perform the start-up and commissioning will be provided
by the equipment manufacturer and will be approved by Saudi Aramco. The resultant data
are to be recorded on the Start-Up and Commissioning Test Results Data Sheet. This section
will provide information on the following topics that are pertinent to UPS system start-up and
commissioning:
Verifying Proper Electrical Connections
Verifying Initial System Set-Up
Simulation of Line Power Source Loss
Verifying Proper Electrical Connections
The purposes for verifying proper electrical connections during start-up and commissioning
of a UPS system are the following: to confirm that no loose connections exist that could arc
and present a hazard to personnel; and to verify that the interconnecting wiring is correct (to
avoid possible damage to the system equipment).
The electrical equipment of a UPS system should not be energized until all electrical
connections have been visually inspected. The visual inspection should include but should
not be limited to the following:
Verify that all electrical components are installed in accordance with the design
documents.
Verify that all field wiring has been installed in accordance with the project
electrical drawings.
Check all electrical terminations, field connections, and vendor equipment for
tightness.
Check electrical conductor insulation for any breaks, voids, or signs of
materials stress.
Verify that electrical conductors are free of any sharp edges or moving parts
that will damage the insulation.
Verifying Initial System Set-Up
The initial system set-up will verify all of the operational functions of the UPS system. The
system set-up will include the following areas:
Initial Conditions
System Setpoints
Calibration Checks
Switching Functions
Initial Conditions
The Electrical Engineer must verify that all the UPS system manufacturer's technical manuals
have been received and that these manuals apply to the specific installation. Many of the
manufacturer's technical manuals are equipment specific, and a non-applicable manual can
create major problems.
The Electrical Engineer must verify that all overcurrent protection fuses have been installed
and are of the correct value. If the fuses are undersized, they can unnecessarily trip. If the
fuses are oversized, they may permit excessive current flows that can result in possible
damage to the equipment.
A check of the available incoming power sources also is an initial condition requirement.
These incoming power sources consist of a preferred ac power source that normally connects
to the inverter circuit and an alternate ac power source that connects to the static switch and
the manual bypass switch. Some installations may further segregate the power through use of
a third incoming ac power source that would connect to the manual bypass switch. In this
case, the alternate ac power source would supply only the static switch.
The Electrical Engineer must verify that the inverter and the battery charger enclosure
ventilation fans properly operate. An inoperable fan or a restricted air flow can produce
excessive temperature in the interior of the enclosure. These excessive temperatures can
cause operational failures and premature electrical component failures.
System Setpoints
System setpoints consist of two types: alarm and control. The purpose for verifying alarm
setpoints during UPS system start-up and commissioning is to check the alarm points of the
monitored parameters. The alarm points monitor selects system parameters and will "alarm"
when a parameter is reached or exceeded. Operating in the extremes of these maximum and
minimum parameters is conducive to component/system failure. The control setpoints are
used to establish the nominal UPS system operating conditions. An initial check of these
control setpoints is necessary to establish functionality and a point of control, as well as to
establish baseline conditions.
Alarm Setpoints- Each UPS system is provided with a number of alarm points. The
parameters that are to be monitored are dependent on the installation and design
requirements. Saudi Aramco design specifications and manufacturer suggestions will
determine which of the system parameters will be monitored by an alarm circuit.
Procedural steps for testing each alarm point are provided in the manufacturer's
technical manual. The following is a list of the alarms that are associated with a
typical UPS system:
dc Input Voltage High Alarm
dc Input Voltage Low Alarm
Alternate Voltage/Sync Source Not Available Alarm
Static Switch Position Indication Alarm
Output Failure Alarm
Enclosure Overtemperature Alarm
The dc Input Voltage High Alarm indicates the point at which the dc input to the
inverter has reached or exceeded a specified maximum operating condition. The alarm
setpoint is adjustable and should be set at a value of +5.0% of the nominal dc input
voltage.
The dc Input Voltage Low Alarm indicates the point at which the dc input to the
inverter has reached or exceeded a specified minimum operating condition. The alarm
setpoint is adjustable and should be set at a value of -5.0% of the nominal dc input
voltage.
The Alternate Voltage/Sync Source Not Available alarm will actuate when the
alternate power source voltage is not available at the static switch. If the alternate
power source is not available, and if an inverter failure occurs, power to the critical
load will be lost. The alternate power source is considered "not available" when the
voltage deviates from the nominal system voltage by +/- 10% or when the frequency
deviates from the nominal system frequency by +/- 5%.
The Static Switch Position Indicator alarm will energize when the static switch
transfers from the inverter to the alternate power source. This alarm, as a result of the
static switch transfer, indirectly indicates that the inverter has failed; therefore, the
subject alarm should be accompanied by an Inverter Output Failure Alarm.
The Inverter Output Failure Alarm will warn of a loss of inverter output power. This
alarm occurs if the output voltage deviates outside of the range of +/- 10% or if the
frequency deviates more than +/- 5.0% of the nominal 60 Hz value.
The Enclosure Overtemperature alarm warns that the inverter equipment is operating
at above the normal temperature. Overheated inverter electrical components can result
in abnormal output voltage and frequency conditions. Continuous overheating of the
electrical components may result in a premature equipment failure.
Control Setpoints- A UPS system is to provide pure, fully conditioned power to the
critical loads. This power is to be controlled and regulated within specific conditions.
Setpoint adjustments are provided to achieve this required regulation and control. The
regulation and control adjustments are as follows:
Output Voltage
Output Frequency
Phase Relationship
Waveform Purity and Harmonic Distortion Level
Static Switch Transfer/Re-Transfer Voltage Monitor
Static Switch Transfer/Re-Transfer Frequency Monitor
Battery Isolation Circuit breaker Shunt Trip
Output Voltage- The general requirements of a UPS system are that the voltage output
from the static inverter must be at the design nominal voltage +/- 10%, at a frequency
of 60 Hz +/- 5.0%, and in-phase with the ac source voltage. The input to the static
inverter can be from the stationary battery or from the output of the battery charger,
and the input must be verified before adjustment of the static inverter output voltage.
The purpose for verifying the output voltage adjustment during UPS system start-up
and commissioning is to ascertain that the inverter is producing an output voltage that
is within acceptable tolerance. Typically, the battery output and the battery charger
output voltage should be in the range of +/- 10% of the dc nominal voltage.
If the battery output voltage is not within specification, the individual cell voltages and
the specific gravities should be checked, and the battery should be charged. If the
battery output voltage does not return to the normal range, additional battery
troubleshooting should be performed. If the battery charger output voltage is within
the proper range, the static inverter voltage can be adjusted on the inverter's internal
control module. If the battery charger output voltage is not within the range of +/-
1.0% of nominal value, the battery charger output voltage should be adjusted.
The static inverter's output voltage is adjusted through a variance in the delay time or
firing angle of the SCRs. The output voltage should be adjusted when no load is
applied to the static inverter. This adjustment procedure is accomplished through
installation of a portable voltmeter on the inverter output. While the portable test
meter is being monitored, the output voltage control that is located on the inverter
electronic control board is adjusted to set the output voltage to the nominal value.
After all of the voltage adjustments have been made, the output voltage should be
rechecked with the static inverter connected to the critical ac loads. Under electrical
load, the output voltage again should be monitored for voltage level abnormal
transients and waveform purity. Adjustment to the firing angle of the SCRs affects
only the magnitude of the voltage and does not directly affect the frequency or the
phase angle of the output voltage.
Output Frequency - After the input voltage has been adjusted, the frequency of the
output voltage should be checked. If the output from the static inverter is not at 60 Hz,
the transfer from the preferred source to the alternate will not be a smooth transfer.
The output frequency from the static inverter should be monitored with the
ac source reference deenergized or disconnected. Deenergization of the ac source
voltage will ensure that the static inverter is not synchronized with an external source
that may prevent adjustment of the static inverter output frequency. A convenient
method to monitor the static inverter output is with an oscilloscope. The oscilloscope
should indicate a 16.7 millisecond period for one complete cycle. If the frequency is
not at 60 Hz, the frequency can be adjusted on the static inverter's oscillator board.
Phase Relationship - When the static inverter's output voltage and frequency are within
specification, the phase relation between the inverter output and the ac line should be
checked. This relationship easily can be seen on a dual trace oscilloscope. The phase
relationship between the two sources should be zero and can be adjusted on the
synchronizing board of the static inverter.
Static Switch Transfer/Re-Transfer Voltage Monitor - The electronic circuit of the static
switch monitors the inverter output voltage. If the output voltage fluctuates outside the
range of +/- 10% of the nominal inverter output voltage, the static switch will
immediately transfer (less than 4.2 milliseconds) to the alternate source. The static
switch will remain in the diverted or alternate position until the following conditions
are satisfied:
Inverter output voltage returns to within +/- 2.0% of nominal output voltage.
Inverter and alternate source are phase-synchronized.
The above two conditions have been maintained for a duration of at least 30
seconds before re-transfer is permitted.
At this time, the static switch will transfer back to the inverter (preferred) source.
Static Switch Transfer/Re-Transfer Frequency Monitor - The electronic circuit of the static
switch also monitors the inverter output frequency. If the output frequency fluctuates
outside the range of 60 Hz (+/- 5.0%), the static switch will immediately transfer (less
than 4.2 milliseconds) to the alternate source. The static switch will remain in the
diverted or alternate position until the following conditions are satisfied:
Inverter output frequency returns to 60 Hz (+/- 2.0%).
The above frequency value has been maintained for a duration of at least 30
seconds before re-transfer is permitted.
Battery Isolation Circuit Breaker Shunt Trip - A two pole circuit breaker is installed in the
dc circuit ahead of the inverter. This breaker is designed to "trip" in the event of a low
dc voltage. A shunt trip circuit in the breaker monitors the dc voltage. If the dc
voltage to the inverter exceeds the -10% range of the nominal dc voltage, the shunt trip
monitoring circuit will energize to trip the breaker in order to protect the battery from
discharging below the final battery voltage. (For the final battery voltage value, the
equipment manufacturer's technical manual is to be consulted.)
Waveform Purity and Harmonic Distortion Level - The waveform of the static inverter
output should be monitored on start-up to ensure that the inverter can produce an
output that is comparable to the manufacturer's specifications. Although absolute
limits on the waveform distortion do not exist, the measured waveform should model
the waveforms that are supplied by the manufacturer. The inverter output should be
checked with a spectrum analyzer for harmonic distortion. Harmonic distortion that is
greater than 4% can cause problems with electronic equipment. If harmonic distortion
exceeds the maximum allowable level of 4%, the equipment manufacturer should be
contacted.
Calibration Checks
Part of the set-up and commissioning of the UPS system, in addition to checking and
establishing alarm and control setpoints, is to verify that the panelmeters are accurate. The
panelmeters provide a convenient means to monitor the important system parameters. The
panelmeters provide a continuous indication of the monitored parameters. The readings
obtained from panelmeters are to be within +/- 2.0% of the readings that are obtained with a
calibrated test instrument.
Switching Functions
The majority of UPS systems have a manual bypass switch. The manual bypass switch is
used during the performance of maintenance and testing functions. Three-phase (3_) systems
also employ panelmeter selector switches. This section provides information on the following
topics that are pertinent to switching functions:
Manual Bypass Switch
Panelmeter Selector Switches
Manual Bypass Switch - The manual bypass switch provides a method to connect the
critical ac loads directly to a reliable source of power with no downtime of the loads.
The inverter then can be isolated for safe inspection, testing, and maintenance. Two-
way bypass switches perform the following functions:
To shunt the power potential around the inverter without interrupting the
inverter output power. Flow of current divides between the bypass switch
contacts and the inverter to ensure that not even a momentary interruption of
power to the critical loads occurs in the event of an inverter failure.
To allow the inverter to be electrically tested and adjusted without interrupting
or affecting power to the critical load. The inverter output is disconnected from
the critical load, but the inverter is still energized from the normal and
emergency sources and can be electrically tested without affecting the critical
load.
To electrically isolate the inverter from the preferred and alternate source of
power and from the critical load in order to permit inspections and maintenance
of the inverter. In this position, the inverter is completely isolated while the
critical load continues to be fed through the bypass contact.
Panelmeter Selector Switches (3_ Systems) - Selector switches, when used in conjunction
with a panelmeter, allow individual three-phase parameters to be monitored with one
meter. In systems that do not require simultaneous continuous monitoring of the
parameters, the use of a single meter and a selector switch is more economical.
Selector switches are provided to monitor the following parameters:
Voltage - Switch positions: A-B, B-C, A-C, L-N
Frequency - Switch Positions: A_, B_, C_, L-N
Amperage - Switch Positions: A_, B_, C_
Simulation of Line Power Source Loss
The purpose of simulating a line power source loss is to verify that a UPS system will
properly operate under the designed conditions to provide an uninterrupted, bumpless transfer
to the alternate source of power.
Two conditions must be observed to ensure the proper operation of the UPS system: the
transfer of power from the preferred power source to the alternate power source and the
transfer of power from the alternate source to the preferred source.
The following sequence of events should be observed during the performance of the
simulated line power source loss test:
When the UPS system is in automatic, and when the preferred source of power
(output of the inverter for a reverse transfer scheme) is available, the inverter
output supplies power to the critical load. In this situation, the input to the
inverter can be the ac preferred source via the battery charger or the stationary
battery.
If any of the following conditions occur, a transfer signal will be generated and
a transfer will occur:
- The inverter output voltage goes outside of the normal range (i.e., _
10% of the nominal voltage).
- The inverter output frequency goes outside of the normal range (i.e.,
_5% of the nominal frequency).
- An external transfer signal, such as the inverter in the current limit mode
of operation, is present.
A line power source loss can be simulated through performance of one of the
following actions:
- Open the dc input breaker to the inverter.
- Open the ac input breaker to the battery charger and open the battery
output breaker.
- Open the battery output breaker and, through use of a variable ac input
source, vary the ac voltage outside of the normal range.
If a transfer inhibit signal is not present, the transfer to the alternate source will
occur. If a transfer inhibit signal is present, the transfer will be blocked and the
corresponding alarm will occur. The following are examples of conditions that
will result in a transfer inhibit signal and a blocked transfer:
- The alternate power source voltage is outside of the normal range (i.e.,
_10% of the nominal voltage).
- The alternate power source frequency is outside of the normal range
(i.e., 60 Hz _5% of the nominal frequency).
- An external transfer inhibit signal, such as a sync disconnect signal, is
present.
The ac alternate source will continue to supply power to the critical loads until
the external transfer signal is removed from the preferred source sensing circuit
and the following conditions are met:
- The inverter output voltage returns to _2% of the nominal voltage and
remains at this value for at least 30 seconds.
- The inverter output frequency returns to _2% of the nominal frequency
and remains at this value for at least 30 seconds.
When the above conditions have been met, the critical load will be transferred
to the inverter output, which is the preferred source of power.
INTERPRETING START-UP AND COMMISSIONING TEST RESULTS
A major function of the Electrical Engineer during the course of a battery and UPS
installation is to monitor and to direct the actions of the maintenance personnel. After the
installation, and prior to placement of the equipment in service, the Electrical Engineer has an
equally important role to monitor and to analyze the results of the installation tests and
inspections. Through an analysis of the results of the tests and inspections, the Electrical
Engineer can determine whether the battery and UPS system installation is acceptable or can
determine what must be done to make the installation acceptable.
This section will cover the following topics that are pertinent to interpretation of start-up and
commissioning test results:
Battery System Start-Up and Commissioning
Battery Charging Start-Up and Commissioning
UPS System Start-Up and Commissioning
Battery System Start-Up and Commissioning
The determination of the acceptability of the battery system relies on the following items:
The completeness of the battery tests and inspections.
The accuracy of the battery system test data.
The correct interpretation of the battery system test data.
The completeness of the tests and inspections is primarily fixed by the data sheets that are
provided to the Engineer from Saudi Aramco and the battery manufacturer. Although the
Electrical Engineer may specify additional tests for the battery, the start-up and
commissioning tests that are presented in this Module normally are more than adequate to
provide the information that is needed to commission a battery.
The accuracy of the battery test data depends on the qualifications and experience of the
maintenance staff and on the application of the test equipment. Interpretation of this data
must be performed by an Electrical Engineer who is familiar with normal and abnormal
conditions that pertain to battery systems.
To begin the interpretation of the results of battery system start-up and commissioning, the
Electrical Engineer will require the following data sheets:
DC/UPS System Start-up and Commissioning Test Results Data Sheet
Individual Cell Terminal Resistance Test Record
Battery Test Record
Battery Acceptance Test Data Sheet
These data sheets are provided in Work Aid 1.
The DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Figure 16 of
Work Aid 1) is divided into four sections:
Pre-Commissioning Checks
Battery System Checks
Battery Charger Setpoints and Calibration Checks
UPS System Checks and Setpoints
The Pre-Commissioning Checks section of the data sheet applies to the Battery Charger and
UPS system as well as the battery system. The Battery Charger data and the UPS system data
will be discussed later in this Module.
The Pre-Commissioning Checks section and the Battery System Checks section of the
DC/UPS System Start-up and Commissioning Test Results Data Sheet should be checked to
ensure that data have been recorded in all of the blanks and that the data sheet has been
properly signed and dated. The Remarks section should be checked for any noted
abnormalities.
The Electrical Engineer also should verify that the Individual Cell Terminal Resistance Test
Record, the Battery Test Record, and the Battery Acceptance Test Data Sheet have been
properly completed and are included in the review package.
Before the battery system equipment data are analyzed, the Electrical Engineer must verify
the satisfactory completion of the Pre-Commissioning Checks. Any abnormalities or
operational conditions that are outside of the nominal operational range for the battery can
affect the outcome of the remainder of the data that were collected. If the Electrical Engineer
determines that one or more of the pre-commissioning checks is unsatisfactory, he must
determine whether this unsatisfactory condition impacts the validity of the remainder of the
results. If the Electrical Engineer determines that the validity of the remainder of the results is
affected, he should ensure that the unsatisfactory condition is corrected and that the affected
start-up and commissioning tests are performed again.
The Battery System Checks section of the DC/UPS System Start-Up and Commissioning Test
Results Data Sheet (Figure 16 of Work Aid 1) consists of seven items that must be verified.
Verification of each item is to be performed in accordance with the procedure and the
acceptance criteria that are located in Work Aid 1.
The first test results to be reviewed are the Individual Cell Terminal Resistance Test Record
(Figure 17 of Work Aid 1). If the terminal resistances are high, they will reduce the output
voltage of the battery. Resistance values that do not meet the acceptance criteria that are
located in Work Aid 1 must be corrected before the startup and commissioning evaluation is
continued.
After verification of satisfactory cell terminal resistances, the Electrical Engineer should
review the Battery Test Record results. The following data on the Battery Test Record
(Figure 18 of Work Aid 1) should be analyzed for each cell:
Individual cell voltage
Specific gravity (temperature corrected to 25oC)
The individual cell voltage should be within the range that is specified by the acceptance
criteria that are located in Work Aid 1. The individual cell voltages also should be checked in
comparison to the other cells of the battery to ensure that the maximum deviation between the
cell voltages does not exceed the values that are specified in Work Aid 1. Any deviation that
is outside of these normal cell voltages indicates a problem with the battery cell and will
affect the overall efficiency of the battery. The individual cell voltages can be off
specification for a number of reasons. The following is a partial list of these reasons:
An improper charge on the battery cell.
A poor intercell connection.
An improper reading by the maintenance staff.
A defective cell.
If the individual cell voltage is off specification, the individual cell voltage should be taken a
second time to determine whether the initial reading was accurate. If the reading was
accurate, the torque and the resistance of the affected intercell connections should be
rechecked, and the battery should be recharged with the proper charging procedure. In any
case, the manufacturer's technical literature should be consulted for additional troubleshooting
steps and for additional corrective actions.
The temperature-corrected specific gravity for each cell should be within the range that is
specified by the acceptance criteria that are located in Work Aid 1. The specific gravity also
should be checked in comparison to the other cells of the battery to ensure that the maximum
deviation between the specific gravities does not exceed the values that are specified in Work
Aid 1. Any deviation that is outside of these normal specific gravity readings indicates a
problem with the battery cell and will affect the overall efficiency of the battery. The specific
gravity readings can be off specification for a number of reasons. The following is a partial
list of the reasons:
An improper charge on the battery cell.
An improper reading by the maintenance staff.
An improper temperature correction was applied.
An incorrect hydrometer was used.
The readings were taken after the battery was watered.
The cell is defective.
If the specific gravity is off specification, the specific gravity should be taken a second time to
determine whether the initial reading was accurate. If the reading was accurate, the
temperature correction calculation should be rechecked; the equipment that was used to make
the measurement should be checked to ensure that it is the correct equipment; and, if required,
the battery should be recharged with the proper charging procedure. In any case, the
manufacturer's technical literature should be consulted for additional troubleshooting steps
and for additional corrective actions.
Individual cells that do not meet the acceptance criteria should be replaced, and the battery
should be recharged in accordance with the manufacturer's recommended charging
procedures.
After completion of the verification of the Battery Test Results, the Electrical Engineer should
review the Battery Acceptance Test Data Sheet (Figure 19 of Work Aid 1). The battery
acceptance test results should indicate that the battery can sustain a specific discharge rate for
a specified time duration in accordance with the manufacturer's rating. The discharge rate
should be a constant current load that is equal to the manufacturer's rating of the battery for
the selected test length. The selected test length should be the time that the battery is required
to supply the critical loads.
Battery Charger Start-Up and Commissioning
The ability to determine the acceptability of a battery charger relies on the following:
The completeness of the battery charger tests and inspections.
The accuracy of the battery charger test data.
The correct interpretation of the battery charger test data.
provided to the Engineer from Saudi Aramco and the battery charger manufacturer. Although
the Electrical Engineer may specify additional tests for the battery charger, the start-up and
provide the information that is needed to commission a battery charger.
The accuracy of the battery charger test data is dependent on the qualifications and experience
of the maintenance staff and on the application of the test equipment. Interpretation of this
data must be performed by an Electrical Engineer who is familiar with normal and abnormal
conditions that pertain to battery chargers.
At the start of the verification of the start-up and commissioning test results, the Electrical
Engineer must check to see that data are recorded in all of the line items that are shown in the
battery charger section of the DC/UPS System Start-Up and Commissioning Test Results
Data Sheet. The Remarks section also should be checked for any abnormalities.
Abnormalities or operational conditions that are outside the nominal operational range for the
battery charger can affect the validity of the collected data. The Electrical Engineer must
determine whether any abnormal conditions exist. If such conditions do exist, the Electrical
Engineer must determine whether the condition has an effect on the validity of the collected
data. If the Electrical Engineer determines that an abnormal condition does affect the validity
of the collected data, the Electrical Engineer should have the abnormal condition corrected
and should have the affected tests performed again before the start-up and commissioning
evaluation is continued.
The data that are recorded in the Battery Charger Setpoints and Calibration Checks section
should be interpreted through use of steps 3a through 3k of the procedure and acceptance
criteria that are located in Work Aid 1.
UPS System Start-Up and Commissioning
The ability to determine the acceptability of a UPS system relies on the following:
The completeness of the UPS system tests and inspections.
The accuracy of the UPS system test data.
The correct interpretation of the UPS system test data.
provided to the Engineer from Saudi Aramco and the UPS system manufacturer. Although
the Electrical Engineer may specify additional tests for the UPS system, the start-up and
provide the information that is needed to commission a UPS system.
The accuracy of the UPS system test data are dependent on the qualifications and experience
of the maintenance staff and the application of the test equipment. Interpretation of this data
must be performed by an Electrical Engineer who is familiar with the normal and the
abnormal conditions that pertain to UPS systems.
At the start of the verification of the start-up and commissioning test results, the Electrical
Engineer must check to see that data are recorded in all of the line items that are shown in the
UPS system section of the DC/UPS System Start-Up and Commissioning Test Results Data
Sheet. The Remarks section also should be checked for any abnormalities. Abnormalities or
operational conditions that are outside of the nominal operational range for the UPS system
can affect the validity of the collected data. The Electrical Engineer must determine whether
any abnormal conditions exist. If such conditions do exist, the Electrical Engineer must
determine whether the condition has an effect on the validity of the collected data. If the
Electrical Engineer determines that an abnormal condition does effect the validity of the
collected data, the Engineer should have the abnormal condition corrected and should have
the affected tests performed again before the start-up and commissioning evaluation is
continued.
The data that are recorded in the UPS System Checks and Setpoints sections should be
interpreted through use of steps 4g through 4x of the procedure and the acceptance criteria
that are located in Work Aid 1.
WORK AID 1: PROCEDURES AND CRITERIA FROM SADP-P-103, IEEE 446,
AND ESTABLISHED ENGINEERING PRACTICES FOR
INTERPRETING START-UP AND COMMISSIONING TEST
RESULTS
Procedure and Acceptable Values for Interpreting Start-Up and Commissioning Data
1. Verify that all of the pre-commissioning checks that are listed in Figure 16, DC/UPS
System Start-Up and Commissioning Test Results Data Sheet (Page 1), have been
satisfactorily completed. Satisfactory completion of the pre-commissioning checks is
indicated by an "X" in the Yes column.
2. Verify that the start-up and commissioning results of the Battery System checks that are
listed on Figure 16, DC/UPS System Start-Up and Commissioning Test Results Data Sheet
(Page 1), are satisfactory.
2a. Verify that all of the required safety equipment is present and operable. The presence
and operation of the required safety equipment is indicated by an "X" in the Yes
column.
2b. Verify that the test equipment and special tools are available. The availability of the test
equipment and special tools is indicated by an "X" in the Yes column.
2c. Verify that the battery rack is assembled and correctly installed. The assembly and
correct installation of the battery rack is indicated by an "X" in the Yes column.
2d. Verify that the battery cells and support equipment are correctly installed. Correct
installation of the battery cells and support equipment is indicated by an "X" in the Yes
column.
2e. Verify that the initial battery cell terminal resistances are satisfactory through comparison
of the resistance values that are recorded on Figure 17, Individual Cell Terminal
Resistance Test Record, with the acceptable values for battery cell terminal resistance
that are listed below:
Battery Cell Terminal Resistances
The acceptable value for battery cell terminal resistance is that no cell terminal
should have a resistance that exceeds 10% or 5__, whichever is greater over the
average of all of the cell terminal resistances.
2f. Verify that the battery test results are satisfactory through comparison of the data that are
recorded on Figure 18, Battery Test Record, with the acceptable values for the battery
test that are listed below:
Battery Cell Temperatures
The acceptable value for battery cell temperature is that no cell should deviate
more than 3
o
C (5
o
F) from any other cell.
Cell Voltage
The acceptable value for battery cell voltage is that no cell voltage should
have a
value that is lower than 2.10 volts (1.215 specific gravity) for lead-acid cells
and
1.29 volts (1.300 specific gravity) for nickel-cadmium cells.
Cell Specific Gravity
The acceptable value for battery cell specific gravity is that no cell specific
gravity should have a value, after corrected for temperature and electrolyte
level,
of more than 10 points (0.010) below the average of all cells.
Battery Compartment Condition
Satisfactory condition of the battery compartment is indicated by an "X" in the
space that is adjacent to the "clean" and the "dry" selections.
Connections and Terminal Conditions
Satisfactory condition of connections and terminal condition is indicated by an "X"
in the space that is adjacent to the "Satisfactory" and the "Tight" selections.
Cell Case Condition
Satisfactory condition of each cell case is indicated by an "X" in the space that is
adjacent to the "Satisfactory" selection.
Plate Condition
Satisfactory condition of the individual cell plates is indicated by an "X" in the
space that is adjacent to the "Good" selection.
Bottom Sediment Accumulation
An ideal sediment condition is indicated by an "X" in the space that is adjacent to
the "None" selection; however, an "X" in the space that is adjacent to the "slight",
"white", or "fine" selections also are acceptable.
2g. Verify that the battery acceptance test results are satisfactory through comparison of the
data that are recorded on Figure 19, Battery Acceptance Test Data Sheet, with the
acceptable values that are listed below:
Battery Discharge Rate
The acceptable value for the battery discharge rate is that the battery discharge rate
must meet the manufacturer's specified battery discharge rate or the battery
discharge rate as determined by the Saudi Aramco Design Engineer.
NOTE: Batteries may be at less than rated capacity when received from the
manufacturer. Unless 100% battery capacity upon delivery is
specified, initial battery capacity can be as low as 90% of the battery
rating. This capacity will rise to the rated value in normal service
after several years of float operation.
Battery Discharge Duration
The acceptable value for the battery discharge duration is that the time period for
the battery discharge rate must meet the manufacturer's specified battery discharge
duration or the battery discharge duration as determined by the Saudi Aramco
Design Engineer. The battery discharge duration is the time period that it takes for
a battery that is under a constant current discharge to reach the specified battery
terminal voltage. The specified battery terminal voltage is a value that is equal to
the specified average voltage per cell (usually 1.75V) times the number of cells.
3. Verify that the start-up and commissioning results for the Battery Charger Setpoints and
Calibration Checks that are listed on Figure 16, DC/UPS System Start-Up and
Commissioning Test Results Data Sheet (page 1), are satisfactory.
3a. Verify that the Enclosure Ventilation Fan is properly operating. Satisfactory operation is
3b. The acceptable values of float voltage range from 2.25 to 2.3 volts per cell, or +/- 1.0%
of the nominal voltage, as recommended by the equipment manufacturer.
3c. The acceptable values for equalize voltage are +/- 1.0% of the nominal voltage for
systems that are rated more than 10 kW. For systems that are 10 kW or less, the
acceptable value is +/- 2.0% of nominal voltage. The nominal voltage is the cell open
circuit voltage as stated by the equipment manufacturer.
3d. The acceptable value for operation of the End of Charge Condition Alarm is +/- 5.0% of
the 1.75 volts per cell setpoint for lead-acid cells and is +/- 5.0% of the 1.10 volts per
cell setpoint for nickel-cadmium cells.
3e. The acceptable value for the Low Charger Output Voltage Alarm setpoint is 2.2 volts per
cell for lead-acid cells and 1.4 volts per cell for nickel-cadmium cells.
3f. The Ground Detection Alarm should operate when the leakage current exceeds 10.0
milliamps. This is a fixed value that is established by the equipment manufacturer.
3g. The acceptable value for the Charger Overvoltage Alarm setpoint is +/- 10% of the
nominal cell voltage, as recommended by the equipment manufacturer.
3h. The acceptable value for the Charger Failure Alarm setpoint is +0, -15% of the nominal
cell voltage as recommended by the cell manufacturer.
3i. The acceptable value for the Enclosure Overtemperature Alarm setpoint is +10%, -
0% of the manufacturer's recommended normal operating temperature.
3j. The Equalize Charge Timer should be set such that the actual elapsed time is within _
10% of the timer setting.
3k. The dc voltmeter (Output) panelmeter indication and the dc ammeter (Output)
panelmeter indication should be within +/- 2.0% of the portable voltage and ammeter
indication's as applicable.
4. Verify that the start-up and commissioning results for the UPS System that are listed
on Figure 16a, DC/UPS System Startup and Commissioning Test Results Data
Sheet (page 1), and Figure 16b, DC/UPS System Start-Up and Commissioning Test
Results Data Sheet (page 2), are satisfactory.
4a. Verify that the Enclosure Ventilation Fan is properly operating. Satisfactory operation is
4b. Verify that the Output Voltage, Frequency, and Harmonic Waveforms that are shown in
Figure 20 are satisfactory in comparison to the manufacturer's technical data.
Satisfactory waveforms are indicated by an "X" in the Yes column.
4c. The acceptable High Inverter dc Input Voltage Alarm setpoint is +10%, -0% of the
nominal inverter input voltage.
4d. The acceptable Low Inverter dc Input Voltage Alarm setpoint is +0, -10% of the nominal
inverter input voltage.
4e. The Alternate Voltage/Sync Source is Not Available at the Static Switch Alarm setpoint
should be set to actuate when the alternate voltage is +/- 10% of its nominal value, or
when the alternate source frequency is +/- 5.0% of the nominal 60 Hz.
4f. The Static Switch Position Indicator Alarm should actuate when the static switch
transfers to the alternate power source.
4g. The acceptable Inverter Output Failure Indicator setpoint is +/- 10% of the nominal
inverter output voltage.
4h. The acceptable Enclosure Overtemperature Indicator setpoint is +10%, -0% of the
manufacturer's recommended normal operating temperature.
4i. The acceptable Auto Synchronization Disconnect Alarm setpoint is +/- 5.0% of the
alternate voltage source frequency.
4j. The Static Switch Transfer to Alternate Source Voltage should occur at +/- 10% of
the nominal inverter output voltage.
4k. The Static Switch Re-Transfer to Preferred Source Voltage should occur at +/- 2.0% of
the nominal inverter output voltage.
4l. The Static Switch Transfer to Alternate Source Frequency should occur at +/- 5.0%
of the nominal inverter output frequency.
4m. The Static Switch Re-Transfer to Preferred Source Frequency should occur at +/- 2.0% of
the nominal inverter output frequency.
4n. The Battery Isolation Circuit Breaker Shunt Trip Monitor voltage should be set to +/-
2.0% of the portable voltmeter indication.
4o. The Inverter dc Input Voltage panelmeter indication should be within +/- 2.0% of the
portable voltmeter indication.
4p. The Inverter ac Output Voltage panelmeter indication should be within +/- 2.0% of the
4q. The Alternate ac Input Voltage panelmeter indication should be within +/- 2.0% of the
4r. The Inverter ac Output Frequency panelmeter indication should be within +/- 2.0% of the
oscilloscope indication.
4s. The Inverter ac Output Amperage panelmeter indication should be within +/- 2.0% of the
portable ammeter indication.
4t. Verify that the Manual Bypass Switch transfer to the Test Bypass position is satisfactory.
Satisfactory operation of the switch transfer to the Test Bypass position is indicated by
an "X" in the Yes column.
4u. Verify that the Manual Bypass Switch transfer to the Full Bypass position is satisfactory.
Satisfactory operation of the switch transfer to the Full Bypass position is indicated by
an "x" in the Yes column.
4v. (3_ Systems) Verify that the panel Voltmeter Selector Switch function test is
satisfactory. Satisfactory operation of each switch function is indicated by an "X" in
the Yes column.
4w. (3_ Systems) Verify that the panel Frequency Meter Selector Switch function test is
satisfactory. Satisfactory operation of each switch position function is indicated by an
"X" in the Yes column.
4x. (3_ Systems) Verify that the panel Ammeter Selector Switch function test is satisfactory.
Satisfactory operation of each switch position function is indicated by an "X" in the
Yes column.
DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Page 1)
Figure 16a
DC/UPS System Start-Up and Commissioning Test Results Data Sheet (Page 2)
Figure 16b
Individual Cell Terminal Resistance Test Record
Figure 17
Battery Test Record
Figure 18
Battery Acceptance Test Data Sheet
Figure 19
Test Results Data Sheet Waveform Record
Figure 20
GLOSSARY
caustic Able to destroy or eat away by chemical action.
cell The basic electrochemical unit that is characterized by an anode and
a cathode and that is used to receive, store, and deliver electrical
energy.
corrosive Having the power to corrode a material.
electrolysis A chemical action that is caused by the flow of electric current
through an electrolyte.
electrolyte A conducting medium in which the flow of electric current takes
place by migration of ions.
hydrometer An instrument that is used to determine the specific gravity of a
fluid.
meniscus The curved upper surface of a liquid column. The surface is
concave when the containing walls are wetted by the liquid and is
convex when the containing walls are not wetted.
NFPA National Fire Protection Association.
open circuit voltage The voltage at a battery's terminals when no current is flowing.
parallax The apparent displacement or the difference in apparent direction of
an object as seen from two different points that are not on a straight
line with the object.
pilot cell A cell that is used to provide statistical data about an installation and
that is chosen to be representative of the entire battery.
root mean square The average root voltage that is applied to an electrical component.
(RMS)
specific gravity The ratio of the density of a material to the density of pure water,
taken as a standard when both densities are obtained by weighing in
air.

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