SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

UPS/DC Electrochemical Battery, Storage and Preservation

Testing
PROJECT TITLE

SATR-P-3101
WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED TEST DATE & TIME

ACTUAL TEST DATE & TIME

ELECTCONTRACTOR / SUBCONTRACTOR

EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

REFERENCE

A. TEST PROCEDURE AND CHECKLIST

A1

Batteries of different types and capacities shall not be mixed unless

authorized by the UPS manufacturer.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.9)

SAES-P-103
Sec. 3.2

A2

Terminals should be kept clean and free of chemical deposits that may
form on the interface between the battery terminal and the battery
connector.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.10)

SAES-P-103
Sec. 3.2

A3

All post-to-post and terminal connections should be tested for proper

resistance after all terminal connections are completed and prior to use
of the battery.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.10)

SAES-P-103
Sec. 3.2

A4

Batteries should be handled with extreme care or they may cause

severe injury. Spilled electrolyte may destroy clothing, burn skin, or
cause blindness. CAUTION- Always wear goggles and rubber gloves
when working with batteries.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.11)

SAES-P-103
Sec. 3.2

A5

Always wear eye protection, and never smoke when in the vicinity of
vented lead-acid batteries. The gases vented are hydrogen and oxygen,
a potentially explosive mixture. If electrolyte gets into the eyes, flush with
copious amounts of water and seek medical help immediately.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.11)

SAES-P-103
Sec. 3.2

A6

Batteries shall be used and stored in an upright position unless they

have been designed for all altitude use.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.11)

SAES-P-103
Sec. 3.2

A7

Insure that lead acid batteries are stored in a charge condition.

(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.12)

SAES-P-103
Sec. 3.2

A8

Verify that storage temperature range is 0 degree Centigrade to 25

degrees Centigrade or in accordance with the manufacturer's
recommendations.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.12)

SAES-P-103
Sec. 3.2

A9

Insure that when stored in a long period of time, it is advisable to keep

them on a very low rate of trickle charge in accordance with
manufacturer's recommendations.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.12)

SAES-P-103
Sec. 3.2

A10

Insure that when such trickle charging is impractical, batteries may be

charged periodically.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.12)

SAES-P-103
Sec. 3.2

A11

Check that battery operation monitoring system shall be implemented for

each bank of batteries to obtain history of the operation of the battery
system and to assist in battery evaluation.
(NFPA 70, NEC 110.3B, NEMA PE 1 Sec. 2.5.13)

SAES-P-103
Sec. 3.2

Page 1 of 8

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO ACTIVITY NUMBER

TEST PROCEDURE ACCEPTANCE CRITERIA

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

SAUDI ARAMCO TIP NUMBER

ITEM
No.

30-Jun-08
DATE APPROVED
QR NUMBER

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

RE-TEST DATE

A12

The cells and monoblocks shall be interconnected using standard

connector used in actual battery installations. The cell opening shall be
closed with the appropriate electrolyte level indicators, vent plugs, flame
barriers or similar.
(NFPA 70, NEC 110.3B)

Page 2 of 8

SAES-P-103
Sec. 3.2

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

UPS/DC Electrochemical Battery, Storage and Preservation

Testing
PROJECT TITLE

ITEM
No.

SATR-P-3101
WBS / BI / JO NUMBER

TEST RESULTS ACCEPTANCE CRITERIA

REFERENCE

A13

Purified water shall be added to the cells if the electrolyte level

approaches the minimum mark.
(NFPA 70, NEC 110.3B)

SAES-P-103
Sec. 3.2

A14

The cells or batteries shall be allowed to remain without a connected

circuit for a period of 90 days, during which time the average
temperature of the electrolyte shall be maintained at (20 2) C. During
this time, the maximum electrolyte temperature shall not exceed 25 C,
and the minimum shall be not less than 15 C.
(IEC 60896-11 Sec. 18.2)

SAES-P-103
Sec. 3.2

A15

After 90 days of storage without a circuit, the cells or batteries shall

undergo a capacity test and the measured capacity shall be corrected.
IEC 60896-11 Sec. 18.3

SAES-P-103
Sec. 3.2

A16

Protective equipment:
The following minimum set of protective equipment for safe handling of
battery and protection of personnel shall be available:
a) Safety glasses with side shields, goggles or face shields
b) Electrically insulated gloves
c) Protective aprons and safety shoes
d) Portable or stationary water facilities for rinsing eyes and skin in case
of contact with electrolyte
e) Class C fire extinguisher
f) Bicarbonate of soda, mixed 0.1 kg to 1 L (1 lb to 1 gal) of water, to
neutralize acid spillage
g) Adequately insulated tools

SAES-P-103
Sec. 3.2

h) lifting device of adequate capacity, when required

NOTE- Some battery manufacturers do not recommend the use of CO2
Class C fire extinguishers due to the potential of thermal shock.
IEEE Std 1188-2005 Sec. 4.2

A17

A18

The following protective procedures shall be observed:

a) Use caution when working on batteries since they present a shock
hazard.
b) Check the voltage to ground (ac and dc) before working around the
battery
c) Prohibit smoking and open flames, and avoid arcing in the immediate
vicinity of the battery.
d) Provide adequate ventilation; follow manufacturer's instruction during
charging
e) Ensure unobstructed egress from the battery work area
f) Avoid wearing of metallic objects
such as jewelry
g) Ensure that work area is suitably illuminated
h) Follow manufacturer's recommendation regarding cell orientation
i) Follow manufacturer's recommendation regarding lifting and handling
of cells
(IEEE Std 1188-2005 Sec 4.3)

When cell temperatures deviate more than 3 C (5 F) from each other

during a single inspection, determine the cause and correct. If sufficient
correction cannot be made, contact the manufacturer for allowances that
must be taken.
IEEE Std 1188-2005 Sec. 5.3.2 b

Page 3 of 8

30-Jun-08
DATE APPROVED
QR NUMBER

SAES-P-103
Sec. 3.2

SAES-P-103
Sec. 3.2

ELECTCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-TEST DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

UPS/DC Electrochemical Battery, Storage and Preservation

Testing
PROJECT TITLE

ITEM
No.

A19

A20

A21

B.

SATR-P-3101
WBS / BI / JO NUMBER

TEST RESULTS ACCEPTANCE CRITERIA

A continuity test will determine the physical integrity of the battery
system, but not necessarily the performance of the battery. This test is
done with the semiannual maintenance, in accordance with the
manufacturer's recommendations, or when internal ohmic
measurements cannot be performed.
IEEE Std 1188-2005 Sec. 6.3
Connection resistance
It is good practice to read and record intercell and terminal connection
detail resistances as a baseline upon installation. It is very important that
the procedure be consistent so as to detect upward changes that could
be caused by corrosion or loose connections. Increased resistance is a
cause for concern and may require corrective action.
Normal
installation resistances vary greatly as a function of the size of the
installation, e.g., from less than 10 W for a large battery to as much as
100 W or more for a smaller battery. The manufacturer should be
contacted for the expected values.
IEEE Std 1188-2005 Annex D.1 & D.2
Pretest requirements:
The following defines the activities and data required prior to initiating a
discharge test.
a) If an equalizing charge is specifically recommended by the
manufacturer, verify that it has been completed more than three days
and less than thirty days prior to the start of the test.
b) Check all battery connections and ensure that all resistance readings
are correct for the system.
c) Read and record the float voltage of each cell/unit just prior to the test.
d) Read and record the temperature of the battery cell/unit to determine
an average battery temperature (suggest 10% or more cells/units).
e) Read and record the battery terminal float voltage.
f) Measure and record individual cell/unit internal ohmic values prior to
the test.
g) Take adequate precautions (such as isolating the battery to be tested
from other batteries and critical loads) to ensure that a failure will not
jeopardize other systems or equipment.
IEEE Std 1188-2005 Sec. 7.2

30-Jun-08
DATE APPROVED
QR NUMBER

REFERENCE

ELECTCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-TEST DATE

SAES-P-103
Sec. 3.2

SAES-P-103
Sec. 3.2

SAES-P-103
Sec. 3.2

TEST EQUIPMENT AND MATERIALS CRITERIA

1. When working on the electrical connections to the batteries, insulated tools should be used. (PE 1-2003 Sec. 2.5.10)
2. The instruments used for voltage measurement shall be voltmeters of an accuracy class equal to 0,5 or better. The resistance of the voltmeters
used shall be at least 1 k/V (see IEC 60051 or IEC 60485).
3. The instruments used for current measurement shall be ammeters of an accuracy class equal to 0,5 or better. The entire assembly of ammeter,
shunt and leads shall be of an accuracy class of 0,5 or better (see IEC 60051 or refer to IEC 60359).
4. For measuring temperature, thermometers shall be used having a suitable measuring range in which the value of each graduated division is not in
excess of 1 C. The absolute accuracy of the instruments shall be at least 1 C.
5. For measuring electrolyte densities, hydrometers or other instruments shall be used with scales so graduated that the value of each division is not
in excess of 5 kg/m3. The absolute accuracy of the instruments shall be at least 5 kg/m3.

Page 4 of 8

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

UPS/DC Electrochemical Battery, Storage and Preservation

Testing
PROJECT TITLE

ITEM
No.

SATR-P-3101
WBS / BI / JO NUMBER

TEST RESULTS ACCEPTANCE CRITERIA

6. For measurement of time, the instruments accuracy shall be 1% or better.

7. The test equipment calibration cycle shall not exceed twelve months.
Schedule Q, Att. IV, Sec. 7

Page 5 of 8

30-Jun-08
DATE APPROVED
QR NUMBER

REFERENCE

ELECTCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-TEST DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

UPS/DC Electrochemical Battery, Storage and Preservation

Testing
PROJECT TITLE

ITEM
No.

30-Jun-08
DATE APPROVED
QR NUMBER

SATR-P-3101

ELECT-

WBS / BI / JO NUMBER

CONTRACTOR / SUBCONTRACTOR

TEST RESULTS ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-TEST DATE

TEST RESULTS ACCEPTANCE CRITERIA

REFERENCE

PASS

FAIL

N/A

RE-TEST DATE

C. TEST RESULTS

D. CONCLUSIONS

ITEM
No.
D1

Specific gravity shall be in accordance with manufacturer's

recommended values.

NETA ATS 2007

7.18.1.1.1.6

D2

Electrolyte level shall be at the manufacturer's recommended reference

point.

NETA ATS 2007

7.18.1.1.1.6

D3

Cell voltage shall be in accordance with manufacturer's published data.

NETA ATS 2007

7.18.1.1.3.2.4

D4

Consult the battery manufacturer for cell internal ohmic values in excess
of 25% between identical cell that are in fully charge state.

NETA ATS 2007

7.18.1.1.3.2.6

D5

Test results are acceptable and in accordance with Saudi Aramco

Engineering Standards and contractual requirements.

Schedule Q
Att. II

REMARKS:

REFERENCE DOCUMENTS:
1. Schedule Q Quality Requirements (Pro Forma Contract), February 2008
2. Acceptance Testing Specifications - NETA (2007)
3. IEEE Std 1188-2005 Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary Applications, 2005
4. IEC 60896-11 Stationary Lead-acid batteries- Part 11: Vented type - General requirements and methods of tests, 2002
5. SAES-P-103, UPS and DC Systems, 02 June 2008
6. NEMA PE 1 Uninterruptible Power Systems (UPS) - Specification and Performance Verification (1-2003)
ATTACHMENT(S):
1. Attachment - 1 IEC-60896-11, Table A.1 and A.2 Test recommendation for stationary batteries
NOTES:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).

Page 6 of 8

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

UPS/DC Electrochemical Battery, Storage and Preservation

Testing
PROJECT TITLE

SATR-P-3101
WBS / BI / JO NUMBER

ITEM
No.

TEST RESULTS ACCEPTANCE CRITERIA

30-Jun-08
DATE APPROVED
QR NUMBER

REFERENCE

ELECTCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-TEST DATE

3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing
states
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
purpose.
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
concerned
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
manufacturer
indicates compliance with appropriate standards or performance in a specified manner.

Contractor / Third-Party

Saudi Aramco

Technician Performing Test*

Name, Title, Department,
Company, Initials and
Date:

PMT Representative

Test Performed Successfully and Results are Acceptable:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

PID Representative
Witnessed Test

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others

Quality Record Approved:

Name, Sign and Date:

Name, Organization,
Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results

Y = YES

Page 7 of 8

N = NO F = FAILED

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO TEST REPORT

SATR NUMBER

UPS/DC Electrochemical Battery, Storage and Preservation

Testing

SATR-P-3101

Attachment 1 -IEC 60896-11

Page 8 of 8

30-Jun-08
DATE APPROVED
QR NUMBER

ELECT-