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220V DC
220V DC
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Battery bank
ii.
iii.
DC Distribution board
- AMCO
Designation
- KPH150P
KPH250P
-75 A
Dimension (mm)
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- 1.2
- 35 0 C
- POLYPROPYLENE
No of cells/bank, NO OF BANKS
2.Charger I & II
Input Voltage
Output Voltage(NOMINAL)
- 220V DC,50 V
Float Voltage
- 240,53.9 V DC +5 % ADJ
Boost Voltage
- 295,66.5 V DC +5 % ADJ
- 30 A , 50 A
40 A
-+1%
3. Distribution Board
Make : Crompton Greaves Ltd. Voltage Rating
Current rating : 300 A
: 220 / 48 V
All modules are switchfuse type. Input module contains one Earthfault relay and
under voltage relay for supervision.
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2. TESTING OBJECTIVE:
2.1
To ensure that all the relevant checklists have been completed for the
battery,battery charger and distribution panel.
2.2
2.3
2.4
To carry tests and checks to ensure that all the components on boards are
operating satisfactorily including cables to all the remote points in the plant
area if available.
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3. TESTING PROPOSAL:
3.1 3 phase AC input supply from switchyard service switchboard will be
made through upto charger input terminal board.
3.2 Battery connections and the battery supply upto charger panel are to be
checked
3.3 Each module of DB will be checked individually and made OK.
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4. SERVICES REQUIRED:
4.1 Calibrated Test Kit
a. Analogue multimeter 0-1000V DC & 0- 10 A DC
b. 500 V DC Megger
c. Digital Multimeter
d. Clamp-on meter for current measurement
e. Phase sequence meter
f. Variable Resistance box of 15 150 K Ohms
g. 1 No. Dual beam/Dual trace oscilloscope
4.2 Electrolyte for cells as per IS-266
4.3 Funnel,jugs,cleaning brush, wire brush etc
4.4 Pure battery grade distilled water
4.5 Variable discharge resistor or Salt solution for testing charger and initial
battery discharge.
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ii.
Safety goggles
iii.
Rubber gloves
iv.
v.
vi.
5.2 PLANT
i .exhaust fan near ceiling
ii. Acid proof ashphault flooring battery room
iii. fire extinguishers must be installed nearby
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DC Distribution board
7.3 All outgoing cabling work completed upto remote end panels
7.4 All outgoing feeders from DC distribution board switched off.
7.5 Exhaust Fan is fitted and commissioned in Battery room.
7.6 Floor is made up of acid proof tiles.
7.7 Safety clearance certificates signed and returned by all concerned.
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COMMISSIONING PROCEDURE:
The following equipments are checked as per their standard checklist
8.2.1 The insulation value shall be checked with 500 V Dc Megger. During this
test, all low voltage circuits & Relays etc,shall be kept shorted.
8.2.2 The panel shall be switched on at no load. For this, first make input switch
Q1 ON & check the voltages at all phases indicated by lamps VD1,VD2 &
VD3 & voltmeter by selector switch VS1 . Now the voltage is connected to
the primary of the Main transformer which steps the voltage down as
required for the specific DC output voltage & isolates AC input line from
Battery circuits. The transformers secondary is connected to the Full
wave rectifier assembly.
The bridge is standard three phase full wave half controlled silicon bridge.
The voltage control is accomplished by the application of a positive pulse
to the gate terminals of the SCR at the desired time. Before the pulse is
applied, the SCR is open and no current flows in the circuit. As soon as
SCR is fired, it operates as a standard silicon rectifier until the forward
current is reduced to almost zero.
8.2.3 Check the no load output voltage at the output terminals
8.2.4 Ensure the output voltage is steady without any trouble for 15 minutes.
8.2.5 Check for annunciation, interlocks etc.
8.2.6 If load is available, the equipment shall be loaded progressively upto rated
value. Check for voltage regulation, free from oscillation, ripple etc by
means of CRO(Cathode Ray Oscilloscope)
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Commence charging not later than 24 hours after connecting all battery
cells.
8.3.5 Give the first portion of charge at a rate of 100 amps for 36 hours with the
continuous monitoring of acid level, specific gravity and cell voltage.
8.3.6 At end of first charging, discharge battery bank through water resistance,
discharge resistor if supplied along with battery cells or halogen lamps at a
rate of ------- for ----- hours.
8.3.7 Give the second charging at the rate of approximately 20 Amps till the
signs of completion of charge observed.
8.3.8 Select any one cell (except the end cell or regulating cell) as pilot cell out
of every rack as given in the layout of the battery bank
8.3.9 Voltage and specific gravity reading from pilot cells will indicate the state
of charging of the whole battery system.
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8.4.1 Take the final I.R. Value of the Distribution board power bus
8.4.2 Ensure that all outgoing circuits are locked in OFF position.
8.4.3 Check that polarities of D.C switch board, battery charger and battery are
matched and proper as defined.
8.4.4 Check that all safety procedures have been observed.
8.4.5 Close the incomer switch of board to charge it
8.4.6 Measure D.C Voltage at the Input
8.4.7 Observe D.C board for any abnormality
8.4.8 If board condition is satisfactory, check that all remote end fuses of
outgoing circuits are removed.
8.4.9 Switch ON outgoing feeders one by one, Record the following for each
circuit
8.4.9.1
8.4.9.2
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8.5.1 To carry out on load test for the Battery E/F relay, connect variable
resistance box of the range of 15 to 150 K Ohms between +ive pole of
board and earth.
8.5.2 Keep selectivity setting plug of E/F relay setting at 3 ms
8.5.3 Cut out resistance slowly to simulate an earth fault and observe the
current in milli ammeter when the relay operates.
8.5.4 Record resistance and current in mA
8.5.5 Carry out this test on each available setting on relay
8.5.6 While doing test observe and record the direction of deflection in the
ammeter. check whether it confirms the pole on which the fault is
simulated.
8.5.7 Repeat 8.4.1 to 8.4.6 on ive pole of the board
8.5.8 Test is declared satisfactory if the operation of the relay confirms with the
setting
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COMPLETION CRITERIA:
220 V DC system for switchyard is ready and All measurements and
remote indication points are recorded and kept along with this schedule.
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