STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
LIST OF CONTENTS
1. PLANT DETAILS
2. TESTING OBJECTIVES
3. TESTING PROPOSALS
4. SERVICES REQUIRED
5. SAFETY PRECAUTIONS
6. EMERGENCY PROCEDURES
7. STATE OF THE PLANT
8. COMMISSIONING PROCEDURE
9. COMPLETION CRITERIA
10. APPENDICES

Page 1 of 15

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 2 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
1. PLANT DETAILS:
The system consists of
i.

Battery bank

ii.

Battery charger Main and Standby

iii.

DC Distribution board

The battery is installed in Switchyard control room.This provides a 220 V DC

supply to the relay and control circuits in the Switchyard control room, Circuit
breaker closing and tripping coil, Isolators
Technical Data :
1. Battery cells
Make

- AMCO

Designation

- KPH150P

KPH250P

Guaranteed AH Capacity at 30 mins

discharge rate at 270 C

-150 AH(220V),250 AH(50 V)

Recommended floating/trickle charging voltage - 1.4 to 1.42 volts

Recommended boost charging voltage

- 1.53 to 1.65 V/Cell

Trickle charging current

-75 A

Boost charging current

-30 A FOR 8 HOURS

Dimension (mm)

- 127 mm x 163 mm x 360 mm

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 3 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
Specific gravity of cell when fully charged

- 1.2

Max. electrolyte temp that cell can withstand cont.

- 35 0 C

Cell container material

- POLYPROPYLENE

No of cells/bank, NO OF BANKS

- 169 (220 V),38(50 V), 2

2.Charger I & II
Input Voltage

- 415 V AC+ 10%

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

Rectifier current limit

- 75 A, 150 A(Auto mode)

37.5 A, 75 A (Man Mode)

Battery current limit

- 30 A , 50 A

Auto charge over current

40 A

Steady state output voltage regulation

(for + 10 % I/p voltage & 0-100 % load variation)

-+1%

3. Distribution Board
Make : Crompton Greaves Ltd. Voltage Rating
Current rating : 300 A

: 220 / 48 V

Short circuit current for 1 sec. : 10 KA

All modules are switchfuse type. Input module contains one Earthfault relay and
under voltage relay for supervision.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 4 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD

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

To complete the connections between the battery/battery charger and the

distribution boards

2.3

To make the distribution board live at 220 V DC in a safe and orderly

manner.

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.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 5 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD

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.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 6 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD

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.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 7 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
5. SAFETY PRECAUTIONS:
PERSONNEL
5.1 The following tools must be available for securing personnels from injuries,
burns
i.

Eye wash bottle

ii.

Safety goggles

iii.

Rubber gloves

iv.

Insulated spanners and tools

v.

5 % to 10 % ammonia or soda solution

vi.

Acid proof aprons

5.2 PLANT
i .exhaust fan near ceiling
ii. Acid proof ashphault flooring battery room
iii. fire extinguishers must be installed nearby

5.3 LIVE TERMINALS/DANGER-PANEL CHARGED warning boards are to be

fit at appropriate places.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 8 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
6 EMERGENCY PROCEDURES:
6.1 First Aid charts for acid injuries and electrical shock will be displayed
6.2 In case of any accident involving acid burns neutralizing solution must be
applied.
6.3 All the persons working on battery shall wear acid proof aprons.
6.4 Emergency telephone numbers for hospital and fire services shall be
prominently displayed.
6.5 Communication device must be installed for informing about any
abnormality to either personnel or equipments if happens

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 9 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD

7 STATE OF THE PLANT:

7.1 Erection of Battery banks,chargers and its associated connections
completed.
7.2 Standard check list for the following plant items are completed
7.2.1 Battery banks
7.2.2. Battery chargers
7.2.3

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.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 10 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
8
8.1

COMMISSIONING PROCEDURE:
The following equipments are checked as per their standard checklist

8.1.1 Nickle-Cadmium Battery cells

8.1.2 Battery Chargers I & II
8.1.3 DC Distribution Board
8.2

TESTING OF BATTERY CHARGERS:

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)

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 11 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
8.2.7 Check for dropping characteristics at higher loads.
8.2.8 Run the equipment for 2 hours and observe stability and check for local
heating.
8.2.9 Check the ripple voltage level (peak to peak) is within the limit, when the
unit is loaded.
8.2.10 Conduct the load test with the use of salt solution if not satisfied with the
result obtained
8.3
FIRST CHARGING OF BATTERY CELLS:
8.3.1 DC Voltage needed for battery charging will be 2 times the no of cells in
battery bank. The initial charging will take approximately 72 hours.
8.3.2 It is of utmost importance that the positive terminal of the battery is
connected to positive terminal of charger. So polarity should be
ascertained.
8.3.3 Check thoroughly to ensure cells are connected in series and all
fastenings and connections are tight. The test polarity of the charging
leads and correct the positive terminal to that of charger.
8.3.4

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.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 12 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
8.3.10 All cell terminals & connections are to be applied with petroleum jelly . No
adjustment should be made which will disturb charging.
8.3.11 When all the cells have been greasing freely and when voltage and
specific gravity deemed to be fully charged and the charging may be
terminated. Then wipe down outside of all cells and clean the floor.
8.3.12 Put the battery system on trickle charging when charging completes.
CAUTION: DONT TOUCH BATTERY TERMINALS WHEN CLEANING
OUTSIDE AND BATTERY AREA. USE PROPER GLOVES AND OTHER
SAFETY MATERIALS
8.3.13 The trickle charge should be adjusted to give optimum battery voltage of
-----------------volts per cells
8.4

ENERGISING OF DISTRIBUTION BOARD:

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

polarity at both ends of circuit

8.4.9.2

voltage at both ends of circuit

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 13 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
8.5

EARTHFAULT RELAY ON LOAD TEST:

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

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 14 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
9

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.

STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500NTPC REF NO : SIM/1/TS/1/

Page 15 of 15

PLANT AREA : 400 KV SWITCHYARD

TESTING SCHEDULE : 220 V/48 V DC SYSTEM FOR SWITCHYARD
10. APPENDICES:
DRAWING :
1. GENERAL ARRANGEMENT OF BATTERY SYSTEM 220 V & 48 VNo: DID-184-F99 & TB-DG-186-316-0421,REV 01)
2. O & M Manual of Batteries and Battery Chargers (No.TB-DG-186-3160419 & 0431).