Commissioning Systems Batteries and Battery Charger PDF

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Commissioning Batteries
And Battery Charger Systems
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Electrical For additional information on this subject, contact

File Reference: EEX30105 W. A. Roussel on 874-1320
Engineering Encyclopedia Electrical
Commissioning Batteries and Battery Charger Systems
Contents Page
Saudi Aramco Applications And Requirements For Batteries
And Battery Charger System............................................................................ 1
Evaluating Battery And Battery Charger Systems Upon Receipt .................... 36
Evaluating Battery And Battery Charger Installation And Testing ................... 38
Battery And Battery Charger System Operational Testing Requirements ....... 43
Requirements For The System Operational Observation Phase .................... 45
Summary ......................................................................................................... 46
Work Aid
Work Aid 1: References For Evaluating Batteries And Battery
Chargers Upon Receipt .................................................................................. 47
Work Aid 2: References For Evaluating Batteries And Battery
Charger Installation And Testing..................................................................... 58
Glossary .......................................................................................................... 61
Saudi Aramco DeskTop Standards

SAUDI ARAMCO APPLICATIONS AND REQUIREMENTS FOR BATTERIES AND

BATTERY CHARGER SYSTEMS
The type and size of batteries and battery chargers that are used in Saudi Aramco installations
are selected through use of a number of factors, such as the connected load, criticality of the
load, and ambient conditions. Details of the selection process for batteries are provided in
EEX 211. This Module will not deal with the actual selection process that occurred early in
the project. This Module will be concerned with the specific items that should be verified and
tested during the commissioning process. Batteries and battery chargers must meet all Saudi
Aramco requirements before they are put into service.
Batteries
An electric cell is a device that directly converts the chemical energy that is contained in
active materials into electrical energy through use of an oxidation-reduction electrochemical
reaction. A battery is formed through the interconnection of one or more cells. These cells
may be connected in series, which increases the voltage of the battery by the product of the
cell voltage times the number of cells; or these cells may be connected in parallel, which
increases the amount of current that is available. The available amp-hours are equal to the
cell amp-hour rating times the number of cells.
Batteries are a source of alternate energy for emergency and standby systems. Batteries may
be used to power dc loads, (such as alarm and security systems) directly, or they may be used
as control power for switchgear, telephone systems, and emergency lighting. Batteries also
may be used indirectly to provide power through rotary or static uninterruptable power
systems, which, in turn, provide power for ac loads. Batteries may also be used indirectly to
provide power for lighting and industrial processes or through standby inverters.
Generally, there are two types of batteries that are selected for emergency or standby service:
lead-acid and nickel cadmium (Ni-Cad). The sealed lead-acid battery, also referred to as a
maintenance-free battery, is a relatively new type of lead-acid battery that is sometimes
specified for use in Saudi Aramco facilities. (As the text below explains, seven other types of
lead-acid batteries are also used.) The specific type of battery that is selected is a result of the
evaluation of many factors, such as projected lifetime, ambient conditions, criticality of load,
and economics. Ni-Cad batteries are more expensive than lead-acid batteries, but they are
more rugged, they require less maintenance, and they exhibit longer life than lead-acid
batteries. The actual process of battery selection is outside the scope of this course, but the
information can be found in the Saudi Aramco text, EEX 211, Introduction to DC/UPS
Systems.
Saudi Aramco DeskTop Standards 1

Lead-Acid Batteries
The lead-acid battery is perhaps the most common type of battery that is used in industry to
supply dc loads. The lead-acid battery consists of a group of electrochemical cells that are
connected in series to generate a nominal dc voltage that is used to supply current to a
specified load. The nominal voltage of the battery is determined by the total number of cells
that are connected in series. The amount of active material that is contained in an individual
cell is the factor that determines the discharge capacity rating of the cell. The rated capacity
of the individual cells is the rated capacity of the entire battery. Although the individual cells
are connected in series, the capacity amp-hour rating of the battery does not increase.
The actual chemical reaction that produces a direct current is obtained through placement of a
lead active material in a dilute sulfuric acid electrolyte. This electrochemical couple produces
a nominal cell voltage of approximately two volts.
All lead-acid cells are constructed of the following basic components that are shown in Figure
1:
• Element
• Cell jar
• Cell cover
• Electrolyte
• High and low electrolyte levels

Basic Components of a Lead-Acid Cell

Figure 1

Figure 2 shows an exploded view of the battery element. The battery element is the key
component of the cell, and it consists of an assembly of positive and negative plates that are
insulated from each other through use of separators. The interaction that occurs between the
battery element and the electrolyte determines the cell's performance characteristics.
Each of the plates consists of a rigid lead alloy that provides physical support for the
relatively porous active materials. The positive and the negative plates are sandwiched
together in an alternating pattern (e.g., negative-positive-negative-positive-negative); a
negative plate is placed at each end of the assembly. Each positive plate is separated from its
neighboring negative plate through use of an insulating material. The insulating material
typically is a thin sheet of microporous rubber or plastic that is ribbed on the side that faces
the positive plate. The positive and negative terminal posts are connected to the positive and
negative plates, respectively.
Battery Element
Figure 2

The cell jar, which was shown in Figure 1, is usually made of a transparent, impact-resistant
plastic material. The cell jar must be large enough to enclose the element, yet it must still
provide sufficient reservoir space above and below the element. The upper reservoir space is
needed to allow for the gradual lowering of the electrolyte level that occurs during normal
operation of the battery. The lower reservoir space serves as a collection basin for the
sediment that is shed from the plates during the expected life of the battery. This sediment
must be kept away from the element to prevent a short circuit between the positive and the
negative plates.
After the element has been lowered into the empty jar, the cell cover is placed over the top of
the jar and is sealed. The terminal posts that are connected to the element protrude through
holes that are located in the top of the cell cover. The cell cover also is fitted with a flame
arrestor vent that allows gases to escape from inside of the cell but that prevents entry of
sparks or flames.
The electrolyte that is used in lead-acid batteries is a dilute solution of sulfuric acid and water.
The ratio of acid weight to water is measured as specific gravity. Pure water has a specific
gravity of 1.000. A typical, nominal specific gravity for a lead-acid storage battery is 1.215 at
25°C (77°F). The specific gravity of the electrolyte gradually drops as the cell is discharged.
When the battery charger recharges the cell, the specific gravity gradually rises back to the
nominal value.
If a battery is to be operated at temperatures that exceed 29_C (85_F) for more than 30 days
per year, a tropical (low) specific gravity electrolyte could be used to increase the life of the
battery. A medium or a high specific gravity electrolyte is also available for special
applications, such as UPS systems, that, in some cases, will reduce the overall battery size that
is required.
As previously stated, all lead-acid batteries contain the same basic components. The major
difference between the various types of lead-acid batteries is the design of the positive plates
that are used in the battery element. The remainder of this section provides information on
the following specific types of lead-acid batteries:
• Plante
• Lead calcium
• Lead antimony
• Sealed (Maintenance-Free)
Plante - The plante lead-acid battery is a lead-acid storage battery in which the active material
of the positive plates is electrochemically developed from pure metallic lead. Modern Plante
lead-acid batteries are available with two types of positive plate constructions: traditional and
Manchester. Both types of plates are shown in Figure3.

The traditional positive plate starts off as a blank (slab) of pure metallic lead. Grooves are
then cut into the surface of the lead blank through use of a combing process. The grooves
increase the surface area of the plate, which increases the capacity of the cell.
The Manchester plate is the most common type of plate that is used in Plante lead-acid
batteries. The Manchester plate is constructed of a heavy antimony alloy grid that is cast with
circular holes. Heavy corrugated strips of high purity lead are then rolled into spiral buttons
or "rosettes" that are forced into the holes that are cast in the grid. Each of the lead buttons
exposes approximately five times more surface area to the electrolyte than a comparable area
on a pasted plate battery. The lead buttons also help to prolong the life of the cell by
providing a reserve supply of unformed lead that is gradually converted to active material
during operation of the cell.
The negative plates of Plante lead-acid batteries are pasted or "flat" plates with a heavy alloy
grid. The construction of these plates will be discussed in more detail in the next section of
this Module.

Positive Plates Used in Plante Lead-Acid Batteries

Figure 3
The following are the major advantages and disadvantages of Plante lead-acid batteries:
Advantages Disadvantages
• Long service life (20 to 25 years). • High cost.
• Smallest amount of positive plate • Poor energy density and poor
growth of all lead-acid cells. power density.
• Very high reliability. • Moderate self-discharge rates
(3%/month).

Plante lead-acid batteries have the highest capital cost of all types of lead-acid batteries. The
cost of Plante lead-acid cells is approximately 3 to 3-1/2 times that of a comparable lead
antimony cell and approximately 2-1/2 to 3 times that of a comparable lead calcium cell.
However, in some applications, the high initial capital cost may be justified by the long (25
year) service life.
The cyclic performance and cycle life of Plante lead-acid batteries, as is the case with all
stationary lead-acid storage batteries, can only be discussed in relative terms. Stationary lead-
acid storage batteries are designed to provide a relatively long calendar service life (more than
ten years) when they are operated under float charge conditions rather than a long cycle life.
Stationary lead-acid storage batteries are normally not rated or guaranteed to deliver a specific
number of equivalent full charge cycles.
When any stationary lead-acid storage battery is subjected to deep and frequent discharges, its
calendar service life will be reduced; however, because of the number of variables that are
involved, the specific amount of calendar service life reduction cannot easily be quantified.
For this reason, the cyclic performance of one type of lead-acid storage battery is generally
only discussed in terms of comparison with another type of stationary lead-acid storage
battery.
The cyclic performance (e.g., the ability to withstand frequent and/or deep discharges) of
Plante lead-acid batteries is far superior to the cyclic performance of lead calcium batteries
and is approximately equivalent to the cyclic performance of lead antimony batteries. Plante
lead-acid batteries are capable of withstanding a moderate amount of cycling with a minimum
loss of calendar service life.
Lead Calcium - The positive and the negative plates of lead calcium batteries are pasted plates.
Pasted plates are constructed by forcing a thick slurry of active material (e.g., a combination
of lead oxides and sulfuric acid) into an open lattice grid. A typical pasted plate grid is shown
in Figure 4. The open lattice grid is cast from an alloy of pure lead and calcium. The addition
of the calcium alloying agent is necessary to increase the mechanical strength of the plate.

Typical Pasted Plate Grid

Figure 4
After the active material is pasted on the open lattice grid, the plates are dried and formed
(activated) by an electrochemical process. The completed plate is porous so that the sulfuric
acid electrolyte can circulate through the active material. The porous construction greatly
increases the surface area of active material that is in contact with the electrolyte, which
increases the capacity of a given sized cell.
The following are the major advantages and disadvantages of lead calcium batteries:
• Medium service life (12-15 years) • Subject to excessive positive plate grid
growth.
• Better energy density and power • Not suitable for deep or frequent

density than Plante batteries. discharges.

• Low self-discharge rates (1%/month)
• Low water consumption
• Medium cost
The cost of lead calcium batteries is more than the cost of lead antimony batteries but is
considerably less than the cost of Plante batteries. On a cursory examination, this medium
range cost, when coupled with the other advantages of lead calcium batteries, makes this
battery appear to be more attractive for most applications than the Plante battery. However, a
closer look at the disadvantages of the lead calcium battery shows that this battery is only
more attractive in non-cycling applications.
The cyclic performance of lead calcium batteries is extremely poor. Of the three major types
of stationary lead-acid storage batteries (Plante, lead calcium, and lead antimony), the lead
calcium battery suffers the greatest loss of calendar service life when it is subjected to cyclic
service. Lead calcium batteries should only be used in float charge, shallow-cycle
applications.
Lead Antimony - The positive and the negative plates of lead antimony batteries are also pasted
plates. The only difference between the construction of lead antimony batteries and the
construction of lead calcium batteries is the addition of an antimony alloying material to the
grid rather than a calcium alloying material. The antimony alloying material, which is similar
to the calcium alloying material, is added to increase the mechanical strength of the plate.
The amount of antimony that is used in the grid varies by weight from about 1.5% to 12%
antimony. The percentage of antimony that is used affects the characteristics of the battery.
High antimony content provides greater grid strength; however, it also results in higher float
current requirements, an increase in water usage, and an increase in the frequency of
equalizing charges towards the end of the battery's service life. Low antimony content
provides more desirable operating characteristics but at the sacrifice of grid strength. If the
antimony content is less than 4%, small amounts of other elements, such as selenium, must be
added to maintain sufficient grid strength. Saudi Aramco does not allow the use of lead
antimony batteries that contain more than 3% antimony.
The following are the major advantages and disadvantages of lead antimony batteries:
• Low cost. • High self-discharge rates
(7%/month).

• Better energy density and power • Short service life (10-12 years).
density than Plante batteries. • High water consumption
• Can be used in cycling service.
Lead antimony batteries have the least capital cost of all lead-acid batteries. The low capital
cost makes this battery an attractive choice for cycling service applications in which the high
water usage is acceptable.
The cyclic performance of lead antimony batteries is approximately equivalent to the cyclic
performance of Plante batteries. Lead antimony batteries can withstand a moderate amount of
cycling with a minimum loss of calendar service life.
Sealed (Maintenance-Free) - Two different versions of sealed (maintenance-free) lead-acid

batteries are available: the gelled electrolyte version and the absorbed glass mat (AGM)
version. The basic technology of both versions of sealed lead-acid batteries is identical in that
they are both recombinant-type batteries. Recombinant-type batteries have positive limited
plate groups that operate on an oxygen cycle.
During battery recharge, oxygen is released at the positive plate, and, when the negative plate
is fully charged, it releases hydrogen. These gases are formed from the decomposition of the
water that is in the electrolyte. Because of the explosive nature of hydrogen, the gases must
be vented out of the battery room, and they must be properly dispersed. In flooded lead-acid
batteries, this electrolyte water loss must be replaced on a regular basis to prevent the battery
plates from drying out.
In sealed lead-acid batteries, the negative plate is designed to be what is known in the industry
as "positive limited" because the battery discharge chemical reaction is stopped when the
positive plate is exhausted. When a sealed lead-acid battery is recharged, the negative plate
never reaches its full charge condition; therefore, hydrogen gas is not released. The oxygen is
released at the positive plate, and it travels to the negative plate through the void paths that are
in the plate separator. At the negative plate, the oxygen combines with the lead in the
negative plate to form lead dioxide. The lead dioxide reacts with the sulfuric acid that is in
the electrolyte to form lead sulfate and water. The water that is created replaces the water that
was consumed at the positive plate to make the oxygen; therefore, water never needs to be
added to the battery, and the battery case can be sealed to prevent evaporation.
The oxygen that is generated at the positive plate creates a positive pressure inside the battery
that is two to three pounds above the ambient pressure. Because of this positive pressure,
sealed lead-acid batteries must contain a relief valve to prevent overpressurization of the

battery in the event of a malfunction, such as a runaway charger. The relief valves are
designed to automatically reseal once the pressure returns to normal.
The following are the major advantages and disadvantages of sealed lead-acid
batteries:
• Long service life (15 to 20 years) in • High cost.
float service. • Short service life (< 10 years) in
• No maintenance. cycling
service
• Reduced battery room/ventilation • Moderate self-discharge rates
(3%/month).
requirements • Not suitable for deep or frequent
• Vertical or horizontal mounting. discharges.
The development of sealed lead-acid batteries for large stationary storage applications is a
relatively recent (within the last ten years) technology and, as such, these batteries are more
expensive than their lead calcium and lead antimony flooded cell counterparts. The cost of
sealed lead-acid batteries is similar to the cost of Plante lead-acid batteries. Plante lead-acid
batteries are described later in the Module. Sealed lead-acid batteries do not perform well in
frequent or deep-cycle applications, and they should only be used in float charge, shallow-
cycle applications.
Nickel Cadmium (Ni-Cad)
Nickel cadmium (Ni-Cad) cells may be either sealed or vented. Some of the sealed-type
incorporate a high-pressure vent as a safety measure. The vent would relieve at 100 to 300
psig. Sealed Ni-Cad battery cells are designed for applications that are lightweight and
portable, and they provide a long operating life. These types of cells are generally used for
small portable electrical equipment that operates on a dc source. The vented-type of Ni-Cad
cell is used for emergency and standby service.
The Ni-Cad cell provides a high discharge rate. Ni-Cad batteries also provide a fast recharge
for emergency engine starting and for standby service. When compared to a lead-acid cell,
the Ni-Cad cell is generally smaller and lighter, and it requires less maintenance than lead-
acid cells. If the cell is overcharged, the resealable vent allows hydrogen and oxygen gases
that are generated by the electrolysis of water to escape to the atmosphere. The vent isolates
the electrolyte so that it cannot pick up carbon dioxide from the atmosphere and become
carbonated. As a result, deionized water must be added at regular intervals.
The Ni-Cad battery also consists of a group of electrochemical cells that are connected in
series to generate a nominal dc voltage that would supply power to a suitably connected
electrical load. The number of cells that are connected in series determines the nominal
voltage rating of the battery.

The electrochemical couple that is used to form Ni-Cad cells is configured through placement
of a nickel hydroxide positive electrode and a metallic cadmium negative electrode in a dilute
potassium hydroxide electrolyte. This electrochemical couple produces a nominal cell
voltage of approximately 1.2 volts.
The following types of Ni-Cad stationary storage batteries will be discussed in this section:
• Pocket-Plate
• Sintered-Plate
Pocket-Plate - Pocket-plate Ni-Cad batteries get their name from the "pocket" strip that holds
the active material of the plates. The pockets are made from very thin, finely perforated strips
of steel that are formed into shallow "U" channels, as shown in Figure 5. The positive active
material, which consists of hydrates of nickel oxide and graphite, and the negative active
material, which consists of cadmium oxide and a small amount of iron oxide, are placed into
the open "U" channel. The open "U" channel is then covered with a similar strip of perforated
steel, and the two strips are crimped together to form a perforated pocket.
A number of these perforated pockets are interlocked edge-to-edge and then cut to the
approximate finished plate width. The interlocked pockets are then rolled to compress the
active material and to form longitudinal indentations in the plate. Each plate group is then
bolted or welded together. The two (positive and negative) plate groups are interleaved and
insulated with plastic rod or mat separators that are inserted into the longitudinal grooves of
the plates. The insulated plate group or element is then inserted into a plastic container or jar.
After the mechanical assembly is complete, the cells are put through an electrochemical
formation process to convert the active materials to their charged condition.

Pocket-Plate Construction
Figure 5
Figure 6 shows a cut-away view of a typical pocket-plate Ni-Cad battery. The following
components are identified in Figure 6:
• Vent Cap/Flame Arrestor

• Cell Container or Jar
• Plate Tab
• Plate Group Bus
• Separating Grids
• Plate Frame
• Plate

Typical Pocket-Plate Ni-Cad Battery

Figure 6

The vent cap/flame arrestor allows the gases that are generated during normal charging and
discharging to escape from the battery, but it prevents the entry of sparks and foreign
material. The vent cap/flame arrestor can be removed to allow access to the interior of the
cell.
The cell container or jar is constructed of translucent polypropylene. The cell container or jar
is the enclosure that holds the individual components of the cell and that contains the liquid
potassium hydroxide (KOH) electrolyte.
The plate tabs are spot welded to the plate frame and to the upper edge or the pocket plates.
The plate tabs provide the electrical connection between the plates and the plate group bus.
The plate group bus connects the plate tabs to the terminal posts of the battery.
The plate tabs and the terminal posts are welded to opposite sides of the plate group bus.
The separating grids separate the plates and insulate the plate frames from each other. The
separating grids are porous, and they allow the free circulation of the KOH electrolyte
between the plates.
The plate frames seal the plate pockets, and they serve as current collectors. The plates in
Figure 6 have horizontal pockets of double-perforated steel strips.
Most manufacturers make three general pocket-plate designs: thin plates, medium plates, and
thick plates. The thin-plate design has a low internal resistance, and it is used in high rate,
short duration (less than 30 minutes) discharge cells. The medium-plate design has an
internal resistance that is similar to the internal resistance of general purpose lead-acid cells.
This plate design is used in median rate, median duration (from 30 minutes to 2 hours)
discharge cells.
The thick-plate design has a high internal resistance, and it is used in very low rate, long
duration (more than two hours) discharge cells.
All vented Ni-Cad batteries have several general advantages over their flooded lead-acid
counterparts. One of these advantages stems from the KOH electrolyte that is used in Ni-Cad
batteries. The freezing point of the KOH electrolyte with a typical specific gravity of 1.190 is
-32°C (-25°F). Because the specific gravity of the electrolyte in a Ni-Cad battery remains
relatively constant from the fully-charged state to the fully-discharged state, the freezing point
also remains relatively constant. In contrast, the freezing point of a fully-discharged lead-acid
battery is essentially the same as the freezing point of water or 0°C (32°F); therefore, lead-
acid batteries are much more likely to freeze than Ni-Cad batteries. Ni-Cad batteries also
make a significantly higher percentage of their current available at lower temperatures than
lead-acid batteries.

Another general advantage of Ni-Cad batteries is that they require much less maintenance
than flooded lead-acid batteries. Ni-Cad batteries can last years without being watered, and
they will not deteriorate when they are left in a discharged condition. Ni-Cad batteries have
been successfully returned to service after being left "on-the-shelf" for 10 to 15 years.
The other general advantages of Ni-Cad batteries include a more rugged and durable
construction (i.e., relatively immune to vibration, shock, and overcharge currents), a long
cycle life, and minimal gas generation on charge and discharge. Also, the gaseous vapors that
are emitted from Ni-Cad batteries are not corrosive to ferrous metals.
The only general disadvantage of Ni-Cad batteries as compared to flooded lead-acid batteries
is the high cost of Ni-Cad batteries. The cost (dollars/kilowatt-hour) of Ni-Cad batteries is
four to ten times the cost of flooded lead-acid batteries. Because cadmium is also more
difficult and expensive to recycle or dispose of than lead, the disposal cost of expended Ni-
Cad batteries is higher than the disposal cost for expended lead-acid batteries. In North
America, large Ni-Cad storage batteries are being phased out of production as a result of the
disposal issues that surround cadmium.
The advantages of pocket-plate Ni-Cad batteries over sintered-plate Ni-Cad batteries are that
pocket-plate Ni-Cad batteries have a lower cost and a longer cycle life, and they do not suffer
a "memory" effect on shallow discharges. The major disadvantage of pocket-plate Ni-Cad
batteries is that they only have about 50% of the energy density of sintered-plate Ni-Cad
batteries.
In contrast to flooded stationary lead-acid batteries, pocket-plate Ni-Cad batteries have a long
cycle life in addition to a long calendar life. Under normal operating conditions, pocket-plate
Ni-Cad batteries can deliver as many as 2,000 equivalent full-charge cycles. The calendar life
of pocket-plate Ni-Cad batteries ranges from 15 to 25 years. Because of the large number of
cycles that this battery can withstand (more than 80 equivalent full-charge cycles per year
over a 25-year calendar service life), cycling has little or no effect on the calendar service life
of pocket-plate Ni-Cad batteries.
Sintered-Plate - Saudi Aramco does not permit the use of sintered-plate Ni-Cad batteries;
therefore, this section is only intended for general information purposes. The primary
applications of sintered-plate Ni-Cad batteries are those applications that require high-power
discharge service in a lightweight compact package, such as aircraft turbine engine starting
circuits.
Sintered-plate Ni-Cad batteries are constructed similarly to pocket-plate Ni-Cad batteries.

The major difference between the two batteries is the way in which the electrodes (positive
and negative plates) are designed. In the sintered-plate design, the active materials are
impregnated into a porous nickel coating that is applied to an iron grid or charge collector.

Sintered-plate Ni-Cad batteries have nickel oxyhydroxide positive plates and cadmium
hydroxide negative plates. The plates are separated by nonconductive, porous materials that
act as a gas barrier and an electrical separator. The electrolyte is a dilute KOH solution, and it
completely covers the plates and separators.
Figure 7 shows the construction of a typical sintered-plate Ni-Cad battery. The battery
consists of a plate pack that contains the positive plates, the negative plates, and the
separators. A terminal comb is placed over the negative plate tabs to connect the negative
plates. A separate terminal comb is placed over the positive plate tabs to connect the positive
plates. The assembled plate pack is then placed in the cell container. A cell cover is placed
on top of the cell container, and it is sealed to the container. A terminal is connected to the
positive terminal comb and to the negative terminal comb. The terminals are used to connect
the battery to the external load. The removable vent cap allows excess gases to escape and a
means to add electrolyte.

Typical Sintered-Plate Ni-Cad Battery

Figure 7

The advantages and disadvantages of sintered-plate Ni-Cad batteries are shown in Figure 8.
Advantages and Disadvantages of Sintered-Plate Ni-Cad Batteries

Figure 8
As was noted in Figure 8, the sintered-plate Ni-Cad battery is more expensive than the vented
pocket-plate battery and many times more expensive than the sealed lead-acid battery.
The average calendar life of a sintered-plate Ni-Cad battery ranges from three to ten years,
and the cycle life ranges from 500 to 2000 equivalent full charge cycles. The cycle life and
calendar life are strongly influenced by the method of operation, the ambient temperature
conditions, and the depth of discharge. The best battery life performance is obtained from
operation at normal temperatures and at moderate (50% average) discharge depths. The life
of sintered-plate Ni-Cad batteries drops when the battery is subjected to frequent deep or
shallow discharges.
Number of Cells

The nominal voltage that is required by the load that is connected to a battery is the factor that
determines the number of cells that are required; however, the voltage at which a battery
system operates is not constant. The voltage fluctuates between minimum and maximum
fixed values dependent on the state of charge. The range of voltages that lies between the
minimum system voltage and the maximum system voltage is the voltage operating "window"
for the battery system. The size (number of cells) of the battery is selected to ensure that the
battery operates inside of the voltage window.
For batteries that supply dc systems, the minimum and the maximum battery system voltages
are based on the voltage rating of the most limiting load. The minimum system voltage is
selected to ensure that sufficient voltage is available to operate the loads at the end of the
battery duty cycle. The maximum system voltage is selected to ensure that the voltage rating
of the loads will not be exceeded when the battery is being recharged. The following are the
minimum and the maximum battery system voltages for Saudi Aramco dc systems:
Nominal System Voltage Minimum System Voltage Maximum System Voltage

12 vdc 10.5 vdc 15.5 vdc
24 vdc 21.0 vdc 30.0 vdc
48 vdc 42.0 vdc 58 vdc
120/125 vdc 105 vdc 143 vdc
240/250 vdc 210 vdc 286 vdc
360/375 vdc 315 vdc 429 vdc
For batteries that supply UPS systems, the minimum and the maximum battery system
voltages are based on the allowable dc input voltage ratings of the UPS system. The
allowable dc input voltage ratings are specified by the manufacturer of the UPS system.
For batteries that supply a combined dc and UPS system load, the minimum and the
maximum system voltages for dc systems should be used.
Because the battery system voltage is the product of the individual cell voltages and the
number of cells that are connected in series, the minimum and the maximum battery system
voltage values are used to determine the minimum and the maximum number of cells that can
be used in a battery installation. The following equation, which is also included in Work Aid
2, can be used to calculate the minimum number of cells that can be used in an installation.
For most applications, the final volts per cell for lead-acid batteries is 1.75, and the final volts
per cell for Ni-Cad batteries is 1.1 volts. If justified by valid engineering and economic
reasons, other final volts per cell values could be used.
The following equation, which is also included in Work Aid 2, can be used to calculate the
maximum number of cells that can be used in an installation:

The maximum cell voltage on charge for lead-acid batteries is the equalizing voltage that is
recommended by the manufacturer. If the manufacturer's data are not available, a value of
2.33 volts per cell can be assumed. The maximum cell voltage on charge for Ni-Cad batteries
is the charging voltage that is recommended by the manufacturer. If the manufacturer's data
are not available, a value of 1.55 volts per cell can be assumed.
After the minimum and the maximum number of cells are known, the actual number of cells
can be specified. The actual number of cells that are specified can be any number that lies
between the minimum and the maximum number. For consistency and ease of specification,
SAES-P-103 contains the following information that lists the number of lead-acid or Ni-Cad
cells that are to be specified for various nominal battery system voltages:
Nominal Battery
System Voltage Number of Cells
(vdc)
Lead-Acid Ni-Cad
12 6 10
24 12 19
48 24 37
120/125 60 92
240/250 120 184
360/375 180 276
The equations serve as a second check to verify that the number of cells listed is correct for
the application.
For example, if a new lead-acid battery is needed to supply emergency power for a dc system
with a nominal voltage of 120 vdc, the number of cells that is required is determined as
follows:
• From the table that is in SAES-P-103, 60 lead-acid cells are required for a nominal
battery system voltage of 120 vdc.
The number of cells that was determined from the table can be verified as follows:
The above calculations verify that 60 lead-acid cells are adequate for this installation.
Duty Cycle

The duty cycle of a battery is defined as the load currents that a battery is expected to supply
for specified periods of time. This information is critical in the determination of the proper
amp-hour rating of a battery.
The proper size of a battery depends not only on the nominal current rating or the kW draw,
but it also depends on the duration of each load (i.e., the duty cycle). Additionally, the battery
size also depends on the sequence in which the load is energized. Careful scheduling of the
load sequence in the duty cycle may allow the cell size to be smaller, which can reduce the
cost of the installation.
Most stationary battery installations are multi-load systems rather than single-load systems.
When a variety of loads are connected to a battery, sudden increases and decreases in current
demands are imposed on the battery. If the high-current loads can be scheduled to energize at
the beginning of the duty cycle rather than at the end of the duty cycle, a smaller-sized battery
can be used. However, if the load is random in nature and could occur at any time during the
duty cycle, the best practice is to assume that the load will energize at the most limiting point
in the duty cycle when its effect will be the most severe.
A duty cycle diagram is a tool that aids in the analysis of the duty cycle and in the
determination of the required battery capacity. A duty cycle diagram shows the total required
battery current at any given time in the duty cycle. To prepare such a diagram, all of the loads
that are expected during the duty cycle are tabulated along with their anticipated start and stop
times.
The loads that have known start and stop times are plotted on the duty cycle diagram as they
would occur. The remainder of the loads should be plotted through use of the following
guidelines:
• If the start time for a load is known but the stop time is indefinite, the load is
assumed to be continuous for the remainder of the duty cycle.
• If the load can occur at random, the load is assumed to occur at the most critical
point in the duty cycle to simulate the worst-case condition. The most critical point
in the duty cycle is the point that controls the size of the battery that is needed.
Figure 9 shows an example of the duty cycle diagram that would be plotted from the
following hypothetical loads:
• L1 represents 50 amps of continuous emergency lighting load for three hours.

• L2 represents 100 amps of momentary switchgear operations load and 250 amps of
momentary motor starting load.
• L3 represents 50 amps of noncontinuous motor load for one and a half hours.
• L4 represents 100 amps of noncontinuous load that starts after 30 minutes and
stops after one hour of operation.
• L5 represents 50 amps of momentary switchgear operations load that occurs during

the last minute of the duty cycle.

Duty Cycle Diagram

Figure 9
Cables
Battery cables are an important link between the battery energy and the load. Cables must be
selected and installed so that they will carry the anticipated current for the maximum length of
time that the battery is expected to discharge into the load. Cables must be insulated with a
conductor insulation that is suitable for the expected operating temperatures and corrosive
effects of the battery electrolyte and gases. The cables must also be sized to provide a
minimum voltage drop at the load. Excessive voltage drop could cause equipment to fail to
operate or to shut down prematurely as the battery voltage decreases during a discharge cycle.
If the battery cables fail to carry the current to load when required, serious consequences may
result, and the function of critical equipment response might be endangered. Battery cables
require only a few major considerations to ensure that their operation is reliable.
Battery cables must be sized of an ampacity that is large enough to carry the load without
exceeding the temperature limitations of the conductor insulation and without excessive
voltage drop. The ampacity of the battery conductors is calculated through a determination of
load current conditions. These conditions are the amount of load current and the maximum
expected duration of the current. The actual AWG size of the conductors is determined
through use of tables, such as tables 310-16 and 310-17 in the National Electrical Code,

NFPA-70. The battery cables that are selected must be stranded copper conductors that are
insulated with a material that is suitable for the nominal battery voltage and that are resistant
to corrosive atmospheres and liquids. Most thermoplastic and rubber insulated conductors are
resistant to acid and caustic atmospheres that are common to battery rooms; special insulation
is not required.
The actual voltage drop due to the resistance of the battery cable conductors can be easily
calculated. The factors that are necessary to calculate the voltage drop are the maximum load
current, the one-way distance to the connected load, and the AWG or kcmil size of the battery
cable conductors. The following formula is used to calculate actual voltage drop:
VD = 2 x L x R x I / 1000
where: L = one-way length of the circuit to the farthest point
R = dc resistance of the conductor per 1000 linear feet
I = maximum expected continuous load current to the load
The dc resistance per 1000 ft. can be found in Table 8 (Conductor Properties) of the National
Electrical Code.
The voltage drop that is calculated from this formula must be no greater than 3% of the
battery nominal voltage.
Battery cables should be connected through use of terminals that are suitable for that purpose.
The cables should be run from the battery's positive and negative terminals to a battery circuit
breaker. This breaker is the disconnect point for the batteries, and it should be equipped with
an undervoltage trip feature that will open the battery's circuit if the battery's voltage drops to
a value of 5% below the battery's final discharge voltage. The requirement for the
undervoltage trip does not apply to batteries that supply emergency or life-critical loads.
Battery Chargers
Saudi Aramco dc systems require battery chargers that operate on constant-potential, semi-
conductor, static-type chargers. These chargers are designed to simultaneously supply dc
power to a float-type battery and to provide power to the connected dc loads. The following
two basic types of chargers are used:
• Static Plate Rectifier

• Solid State Rectifier

Static Plate Rectifier
The static plate rectifier can contain selenium discs or a group of copper or aluminum discs
that contain oxidized selenium or silicon on one side. The discs are clamped together and
have electrical connections on both sides. The discs are supported on an insulated shaft that is
secured through use of insulator clamps at each end. The static plate rectifier is mounted in
the battery charger housing through use of a mounting clasp that is connected at the ends of
the static plate rectifier. Figure 10 shows a single-unit static plate rectifier.
The static plate rectifier converts an ac input to a dc output. The static plate rectifier
accomplishes this conversion by allowing current to flow only in one direction. When an ac
voltage is applied to the static plate rectifier, current can flow from the oxidized side of the
disc to the adjacent copper or aluminum side, but current cannot flow in the opposite
direction. This rectification principle is known as half-wave rectification.

Static Plate Rectifier

Figure 10
Figure 11 shows two possible ways that static plate rectifiers can be configured to produce a
dc output. Figure 11A is a half-wave rectifier circuit. In this circuit, an ac voltage (EAC) is
applied to the circuit through the transformer secondary winding. The static plate rectifier
only allows current to flow in one direction through the load. The voltage that is applied to
the load will only occur during one half of the applied ac sinewave; therefore, the shape of the
resultant EDC is a series of half peaks and flat spots.
Figure 11B shows a full-wave rectifier circuit. The full-wave rectifier also receives ac power
from a transformer secondary winding; however, two static plate rectifiers are connected in
this circuit. The load is connected between the static plate rectifiers and a center tap of the
transformer. The two static plate rectifiers are electrically connected so that one rectifier
conducts on the positive half-cycle of the ac supply voltage, and the other rectifier conducts
on the negative half-cycle of the ac supply voltage. The output (EDC) to the dc load is a full-
wave voltage.

Static Plate Rectifier Operation

Figure 11
The static plate rectifier replaced the old motor-generator systems. Because a static plate
rectifier has no moving parts, it is smaller and requires less maintenance than the motor-
generator systems. One disadvantage of the static plate rectifier is the heat that is generated
from the flow of current through the resistance of the oxide layer. This heat decreases the
efficiency and increases the cost of operating static plate rectifiers.
Solid State Rectifier

The solid state rectifier-type of battery charger uses power diodes and/or silicon controlled
rectifiers (SCR's) to convert ac to dc. Figure 12 shows a simplified diagram of a solid state
rectifier. The operation of the solid state rectifier is very similar to the operation of the static
plate rectifier. The diodes that make up the solid state rectifier only allow current flow in one
direction. The diodes are arranged to provide a path for current flow during each half cycle of
the input ac sinewave. The input ac sinewave is supplied to the solid state rectifier from the
multi-tap transformer secondary. Multi-tap transformer secondaries permit a coarse
mechanical adjustment of the voltage that is supplied to the dc load.
During the positive half of the ac sinewave, diodes D1 and D4 conduct, which allows current
flow to the system battery from negative to positive. During the negative half of the ac
sinewave, diodes D2 and D3 conduct, which also allows current flow to the system battery
from negative to positive. The diode pairs alternately conduct as long as an ac sinewave is
applied that maintains dc current flow to the system battery from negative to positive. The
resultant output wave shape that is supplied to the system battery is also shown in Figure12.
The major advantages of the solid state rectifier are that it is smaller and more efficient than
the static plate rectifier. The main disadvantage of the solid state rectifier is that it costs more
than the static plate rectifier.

Solid State Rectifier

Figure 12
Current and Voltage Ratings
The standard continuous-duty direct current output ratings of Saudi Aramco battery chargers
must be one of the following values:
1A, 3A, 6A, 12A, 15A, 20A, 25A, 35A, 50A, 75A, 100A, 150A, 200A
Battery chargers that are larger than 200A must be rated in 100A increments.
The ac input voltage ratings are based on the available ac voltage and the required system
output voltage. The following are the nominal ac input voltages for Saudi Aramco battery
chargers:
• 120 vac
• 208 vac
• 240 vac

• 480 vac
The output voltage ratings of a battery charger are dictated by the type of battery that the
charger is intended to charge. The output voltage ratings of the battery charger are based on
the float, equalizing, and final volts per cell of the battery to which it is connected. The
maximum voltage output of the battery charger is equal to the following:
Battery charger maximum output voltage = Equalizing voltage per cell x number of cells
Figure 13 shows the typical volts per cell ratings for different types of batteries. The float,
equalizing, and final volts per cell ratings are multiplied by the number of cells that are in the
battery to determine the necessary battery charger output voltage rating.
Typical Volts Per Cell Ratings for Different Battery Types

Figure 13
Operational Requirements
The operational requirements for Saudi Aramco battery chargers fall into the following
categories:
• Output Regulation
• Controls
• Filters
Output Regulation
The voltage output of a battery charger must be regulated to ensure that the proper charge
voltages are applied to the battery. Charge voltages that are outside of the tolerances of the
battery could cause excessive gassing in the cells. The exact amount of output voltage control
that is required depends on the rated size of the battery charger and the type of charge that is
being performed. The following are the output voltage regulation requirements for Saudi
Aramco battery chargers:

Battery Charger Size Float Operation Mode Recharge (Equalize) Operation

Mode
< 10 kW +/- 1% +/- 2%
> 10 kW +/- 1% +/- 1%
Battery charger output regulation also refers to the battery charger's ability to maintain the
rated output during operation of the battery charger. A battery charger must be able to
maintain nominal rated voltage output during load changes, battery removal, and variations in
the input voltage. The battery charger output voltage must return to within the previously
mentioned limits within two seconds when the load is changed or when the battery is
removed, and no voltage variation should result in exceeding the rated output voltage. The
battery charger also must maintain an output voltage that is within the specified voltage
tolerances during variations in the battery charger input voltage.
Controls - Separate and independent controls are required for the adjustment of the float and
recharge (or equalizing) voltage. The battery charger must provide the following ranges of
float voltage output control at its nominal ac input voltage and half load:
Adjustment Range Per Cell

Lead-Acid Cells 2.15 - 2.25 VPC
Ni-Cad 1.40 - 1.47 VPC
The battery charger should also provide the following ranges of equalizing voltage control at
its nominal ac input voltage and half load:
Adjustment Range Per Cell

Lead-Acid Cells 2.25 - 2.40 VPC
Ni-Cad Cells 1.50 - 1.65 VPC
The following formula is used to calculate the required float and equalizing voltage control
ranges for battery chargers:
Charger Output Voltage = VPC x Number of Cells
For example, the required float and equalizing voltage control range for a 60-cell, lead-acid
battery is calculated as follows:
Float Voltage Adjustment Range:

Minimum Charger Output Voltage = VPC x Number of Cells

= 2.15V x 60
= 129V
Maximum Charger Output Voltage = VPC x Number of Cells
= 2.25V x 60
= 135V
Equalizing Voltage Adjustment Range:
Minimum Charger Output Voltage = VPC x Number of Cells

= 2.25V x 60
= 135V
Maximum Charger Output Voltage = VPC x Number of Cells
= 2.40V x 60
= 144V
The battery charger must also have an input circuit breaker and an output circuit breaker or
disconnect switch. The input circuit breaker must have an interrupting capacity that is equal
to or greater than the available short-circuit current. The minimum capacity is 14,000
symmetrical rms amps. Current-limiting fuses may also be provided to meet the short-circuit
current requirements. The output circuit breaker or disconnect switch must be able to
simultaneously disconnect both output lines.
Supervisory Controls
The battery charger should be equipped with the following supervisory control circuits:
• End of Discharge Relay Circuit - The end of discharge relay senses the battery bus
voltage and actuates when the battery has discharged to a predetermined level.
The end of discharge relay should activate when the battery voltage equals 1.75
VPC for lead-acid batteries and 1.10 vpc for Ni-Cad batteries. The setpoint of the
relay should be adjustable from +5% to -5%. Operation of this relay indicates that
the battery needs to be charged.
• Ground Detection Relay Circuit - The ground detection relay senses ground faults
on the positive or the negative battery bus. Operation of this relay indicates the
presence of a ground fault.

• Equalizing Timer Circuit - The equalizing timer allows unsupervised control of the
equalizing charge. The timer is manually set to the desired equalizing time period.
When the battery charger is placed in the equalize charge mode, the timer
automatically returns the battery charger to the float charge mode after the preset
time has elapsed.
• Low Voltage Relay Circuit - The low voltage relay provides an indication that the
dc output voltage has dropped below a preset value. This relay must be adjustable
to allow for field settings of the minimum battery output voltage.
• Overvoltage Relay Circuit - The overvoltage relay provides an indication that the
dc output voltage has increased above a preset value. The relay must be adjustable
to allow for field setting of the maximum battery output voltage.
• Charger Failure Relay Circuit - The charger failure relay provides an indication of
a loss of the charger's dc output. The battery charger failure relay actuates on a
charger output failure regardless of the cause. The charger failure relay is intended
to alert the operator that the charger is no longer in operation, but it does not
provide an exact indication as to the cause of charger output failure.
• Low Current Relay - The low current relay provides an indication that the dc
output current of the battery charger has dropped to a value that is less than two
percent of the rated output.
Filters
Filters are placed on the output of a battery charger to reduce the ac ripple that is in the dc
power that is supplied to the system load. The filter requirements for Saudi Aramco battery
chargers vary dependent on the size of the battery charger and the type of dc load.
The ac ripple voltage of battery chargers that are rated for 10 kW or less should be filtered to
a maximum of 30 mV rms or 100 mV rms dependent on the requirements of the connected
load. For most applications, the ripple voltage is required to be less than 1-2% of the nominal
dc voltage, with a +/- 10% line voltage deviation and with a load variation of 0-100%. The
battery chargers that supply dc systems that are dedicated to only emergency lighting systems
do not require filters.
Environmental Ratings

Battery chargers normally are operated inside of buildings that are air conditioned to 25°C
(77°F). However, in the event of a loss of air conditioning, the battery chargers must be rated
to operate for a period of eight hours in the following environment:
• Ambient temperatures that range from 0°C (32°F) to 50°C (122°F).

• Relative humidity up to 100%.
• Sand, salt, and dust-laden atmosphere.
Ancillary Items
There are several ancillary items that are necessary to support the operation of battery
systems. These items include the battery room, a ventilation system, and showers or eyewash
stations. Battery rooms are constructed with features that provide isolation of the battery and
its associated components from other areas of a facility. Because most batteries emit some
amount of hazardous vapors, the atmosphere that surrounds the battery must be properly
vented. Ventilation systems ensure that an accumulation of hazardous gases will not occur.
Within battery rooms and in close proximity of the battery, emergency showers or eyewash
stations are installed for the safety of personnel. Personnel must have quick access to these
safety items any time that routine maintenance is performed or other work is done that
involves the batteries. During the commissioning process, these items must be inspected to
verify that they are correctly installed and that they will function properly.
These ancillary items must be carefully scrutinized during the commissioning process to
ensure that all the required components are present and that they are installed correctly and in
accordance with the governing standards, such as the National Electrical Code, NEMA PE 5-
1985, Saudi Aramco Engineering Standards, and Saudi Aramco Materials Systems
Specifications.
Battery Rooms
The battery room is constructed to accommodate the battery and its associated equipment with
enough area to allow easy access to the battery for routine maintenance. The actual working
space is determined through use of calculations that are primarily based on the type, size, and
number of cells of the battery. The minimum height of battery rooms should be no less than
three meters, which allows any H2 to accumulate far away from the tops of the cells. The
high ceiling also contributes to a larger overall volume of the battery room, which tends to
reduce the overall concentration of H2.
The battery room should be designed with sufficient working space around the battery. A
minimum of 1 m (3 ft.) of work space is required on all four sides of the battery. This
measurement is the distance from the exposed live electrical components and the associated

equipment to ground. Space in the battery room must also be provided for the easy
movement of equipment in and out of the room and for ease of maintenance. Finally, the
battery room should be designated as a battery room only, and it should not be used as a
storage room or a supply room.
The surface of battery room floors and walls are sealed to prevent the leakage of gases to
adjacent rooms or spaces. The lower 150 mm (6 in.) of the wall and the floor are additionally
covered with a protective paint that is resistant to acids and caustics. This protective paint
ensures that a spill of electrolyte will not damage the floor or leak into adjacent areas.
Penetrations through the battery room walls should not be more than 2.1 m (7 ft.) from the
floor except for air conditioning and ventilation ducts. Where these types of penetrations
exist, they must have vapor-tight seals around them, which ensures that any collection of H2
gas will be expelled through the ventilation system ducts.
Battery rooms are equipped with doors that open out and away from the battery; in the event
of an emergency, rapid exit of personnel is not impeded. Additionally, an inward opening
door would tend to seal itself closed if pressure in the battery room were to suddenly increase
as the result of fire or explosion. The battery room door should not contain any sort of device
that would prevent the door from opening.
Lighting fixtures that are located in battery rooms are suspended from the ceiling so that the
fixtures will be below a level where H2 gas would accumulate. Lighting fixtures are
positioned directly over the battery racks for the best illumination of the cells and battery
racks. The lighting fixtures should be listed or labeled for the specific purpose, and they
should be resistant to corrosion that is caused by acid fumes. Switches for lights and other
similar devices are installed at least 1.5 m (5 ft.) from the battery cells.
Detailed information on the method of calculating the size of the battery room can be found in
EEX 211.05.
Ventilation
Battery room ventilation systems are designed to prevent a concentration of H2 gas that is
greater than 2%. Two percent is a concentration that is considered adequate for safety.
Concentrations of less than 2% are not considered sufficient to allow an explosion.
Because adequately-sized exhaust ducts permit the ventilation system to supply positive air
pressure, most battery rooms in Saudi Aramco facilities will not have exhaust fans. This
positive air pressure will be great enough to maintain the correct amount of air exchange in
the battery room. Battery rooms that meet the battery room ventilation requirements of Saudi
Aramco are not classified as hazardous locations and, therefore, are not required to include
explosion-proof devices or wiring methods.

If the type of battery that is installed in a Saudi Aramco facility is a lead-acid battery, the
battery room must be air conditioned. The air conditioning system must be able to maintain
the temperature in the battery room at 25_(77_F). If the area in which the battery is located is
unmanned and if air conditioning is not feasible, a Ni-Cad battery is normally selected instead
of a lead-acid battery, and air conditioning is not required. Air-conditioned rooms must not
contain return air ducts that would allow corrosive fumes or H2 gas to mix with the building
air.
Detailed information regarding the methods of determining the ventilation requirements can
be found in EEX 211.05.
Showers/Eyewash Stations
Battery rooms in Saudi Aramco facilities will have floor drains to accommodate eyewash and
shower installations. Eyewash stations are installed within the battery room so that a worker
can immediately flush his face or eyes with water in the event of an accidental splash of
electrolyte into the employee's face or eyes. Large battery rooms may be outfitted with
emergency showers that would allow a worker to quickly wash large spills of electrolyte from
his body. If eyewash stations or shower facilities are installed, the floor of the battery room
must include one or more floor drains. The drains must be installed in accordance with the
requirements of SAES-P-060, Saudi Aramco Plumbing Code. This code specifically requires
that the battery room be provided with a floor drain that is trapped and vented to serve
eyewash facilities and washdown of electrolyte spills.
Some of the particular requirements for eyewash stations and emergency showers are
specified in SAES-B-069, Emergency Eyewashes and Showers. The following is a summary
of those requirements as they apply to battery rooms:
• Eyewashes and showers must be constructed of material that is resistant to

corrosion from the effects of the battery room atmosphere. The plumbing that is
connected directly to the eyewash station or shower must be constructed of
galvanized pipe, and the other piping from the supply may be PVC, CPVC, or
copper. The connection branch may also be galvanized pipe if it supplies only the
eyewash and shower.
• The eyewash station and shower must be supplied from a suitable potable water
supply that is certified to be suitable for the purpose by Saudi Aramco's Medical
Service Division.

• The eyewash and shower must be able to provide a continuous flow rate for at least
15 minutes at a pressure that is no greater than 207 kPa (30 psig) and at a
temperature that is not greater than 37.8_(100_F) except for the short period of
time where water is naturally heated from the environment by above-ground
piping. The pressure must be maintained through use of pressure controllers or
self-regulating orifices that prevent the pressure from being greater than 207 kPa if
the system is capable of delivering higher pressure at the eyewash and shower
outlets.
• The shower and eyewash stations must be located no closer than 3 m (10 ft.) and
no further than 15.2 m (50 ft.) from the nearest battery cell. The shower and
eyewash stations must also be easily accessible without going through doors or up
or down stairs, and it must be adjacent to the normal exit from the battery room
and in a well-lit area.
• The eyewash and shower area must be indicated by a background area that is
painted with alternate green and white diagonal stripes that are approximately 152-
mm wide and that cover an area 1 m wide by 2 m high. A sign that indicates both
stations and the emergency procedures for each must be posted.
• The eyewash and shower stations may be equipped with an alarm that is activated
whenever either facility is operated. The determination of whether an alarm is
needed is made by the Industrial Hygiene Unit of the Medical Services.
• During the commissioning of battery systems, the installation of showers and

eyewash stations must be carefully inspected to ensure that they meet the
requirements of SAES-B-069 and that they function properly.

EVALUATING BATTERY AND BATTERY CHARGER SYSTEMS UPON RECEIPT
The components of battery systems must be evaluated upon receipt to ensure that they meet
the relevant Saudi Aramco Material Standards and Specifications. This verification should be
performed as soon as receipt of the equipment occurs so that any discrepancies that are noted
can be resolved before the equipment is installed. The primary focus of this verification is to
ensure that the equipment is not damaged and that the nameplate data and manufacturer's
information that are provided correspond to the electrical drawings and material and
equipment specifications.
Verify Against Specification
Many items should be verified and inspected during the receipt inspection of battery systems.
These items include the battery cells, the battery racks, the interconnecting links, the battery
charger, and ancillary items, such as ventilation equipment.
Battery cells must be verified against the information that is provided on the data schedule to
ensure that the type of battery that was received is the type of battery that was specified on the
data schedule. This verification includes a careful review of the manufacture's literature,
which should accompany the battery and associated hardware, for compliance with the Saudi
Aramco specifications.
The information that is contained in the manufacturer's data should indicate that the battery
will meet the load requirements as described on the data schedule. This information is
normally provided by the manufacturer in the form of a load vs. time graph of battery cell
performance.
The battery charger should be inspected in a manner that is similar to the inspection for
battery cells. That is, the battery charger should be verified against the data specification
sheet to ensure that it meets all the requirements that are listed, as well as compliance with
Saudi Aramco Materials Systems Specifications 17-SAMSS-514 and NEMA PE 5-1985. The
battery charger receipt inspection should include a verification of hardware and accessory
equipment to ensure that all the components are on hand before installation begins.
Verification of all accessory equipment that is specified in the data schedule, such as relays,
alarms and indicating devices, and protective devices must be completed.
The battery charger enclosure must also be inspected upon receipt to verify that is meets the
requirements that are specified in 17-SAMSS-514 and the requirements of NEMA ICS 6,
Type 1 enclosure.
Other items that are associated with the battery and battery charger system must be accounted
for during the receipt inspection. The material and equipment schedule that accompanies the
electrical drawings for the battery system installation should be the reference that is checked
when this receipt inspection is performed. Any missing or damaged items should be

identified as soon as possible so that corrective action can be taken and the project progress is
not delayed.
A complete and detailed description of these inspections and verifications is contained in

Work Aid 1.
Physical Inspection
At the same time that the verification of the battery and battery charger system is confirmed
against specification, a complete physical inspection should be performed. The items that
should be visually and physically inspected are briefly described in the following paragraphs.
Details of this physical inspection are included in Work Aid 1.
The battery cells must be visually inspected to ensure that the manufacturer took the proper
steps to prevent damage and contamination of the cells during shipment. Proper
documentation that explains the shipping and storage procedures should accompany the
batteries and associated equipment.
A physical inventory of all the major items of the accessory equipment must be performed.
Battery hardware, such as intercell connectors, terminal connectors, and rack hardware must
be accounted for and inspected for compliance with specifications and for indication of
damage.
The battery rack and associated hardware should be visually inspected to verify that they are
of the correct size and material composition in accordance with the drawings and
specifications. This inspection includes verification that the rack framework is properly
coated with the specified protective material to prevent corrosion.
Physical inspection includes verification of the inventory of all required accessories, such as
shower and eyewash equipment, safety protective gear, tools, and test equipment, as well as
the battery charger accessory devices.

EVALUATING BATTERY AND BATTERY CHARGER INSTALLATION AND

TESTING
The commissioning of batteries and battery chargers must include a series of installation
checks and tests to confirm that the battery system will function as designed. The Engineer
should evaluate the results of these tests and check points, and he should reconcile any
discrepancies that are identified. A battery system that has not met commissioning criteria but
that is allowed into service can lead to a catastrophe.
Batteries
The battery cells should be inspected to verify that they are correctly installed on the battery
racks. The intercell connectors, battery cables, and connection to the battery disconnect
switch should be inspected to verify that these components are properly installed. The bolts
for the intercell connectors and battery cable terminals should have been applied to the
specified torque for the given size bolt.
When battery cells are inspected, the inspection personnel should verify that the battery cells
have been filled with the correct type electrolyte at the correct specific gravity. The
inspection personnel should also verify that the electrolyte level is within the upper and lower
indicating lines on the cell jar.
The inspection personnel should also verify that the battery rack has been properly assembled
and that all metal parts are manufacturer. Prior to the battery cell installation, the inspection
personnel should ensure that battery cell covered with the protective coating that is supplied
by the internal resistance measurements have been taken and recorded.
Electrolyte
The battery electrolyte for lead-acid batteries consists of a dilute solution of sulfuric acid. For
Ni-Cad batteries, the battery electrolyte consists of potassium hydroxide. After lead-acid
battery cells have been filled with electrolyte, and after the battery receives its "freshening
charge," the specific gravity of each cell must be read and recorded. The freshening charge
must not be applied to the battery unless the electrolyte level is above the low-level line on the
cell jar. The freshening charge must be applied for a period of time that is specific for each
type of lead-acid battery and the required specific gravity. Figure 14 shows the charging time
and per cell voltage that are required to obtain the desired specific gravity that is specified by
the battery manufacturer.

Charging Time and VPC to Obtain Desired Specific Gravity

Figure 14
During the freshening charge process, the electrolyte temperature must be monitored, and it
should not be allowed to exceed 110°F (43°C). The charging should be interrupted and the
battery should be permitted to stand open circuited if the temperature exceeds 110°F (43°C).
When the cells cool down to 100°F (38°C), the charging may be resumed.
When the battery has been properly filled and charged in accordance with manufacturer's
recommended procedures, the battery is then placed on the float voltage. This voltage should
be provided by the battery manufacturer; Figure 15 provides the average volts per cell for
float charge based on the nominal specific gravity for lead-acid cells. After the battery has
been initially charged and has been on float charge for at least 72 hours, specific gravity
readings can be taken. The specific gravity readings should be corrected for temperature. For
every 3°F (1.67°C) above 77°F (25°C), one point (.001) should be added to the specific
gravity reading. For every 3°F (1.67°C) below 77°F (25°C), one point (.001) should be
subtracted from the hydrometer reading.

Average Float Volts Per Cell for Nominal Specific Gravities Listed
Figure 15
Chargers
After the installation is complete, battery chargers should be checked for the following items:
• The battery charger wiring from the ac supply to the charger and the dc output
conductors (battery cables) should be checked for correct wiring practices.
• The size of conductors and type of insulation should be verified.
• The conductors should be checked to verify that they are insulated stranded copper
conductors with a thermoplastic insulation that is suitable for battery room
installation.
• The battery charger should be checked to verify that it is attached to the equipment
ground circuit of the ac supply in accordance with Article 250 of the NEC.
Figure 16, NEC Table 250-95, provides the required size of the equipment grounding
conductors for battery chargers.

NEC Table 250-95: Sizes of Equipment Grounding Conductors for Battery Chargers
Figure 16
The charger output is checked for proper operation through verification of the output
conditions. The settings for the float voltage and for the equalize voltage should be verified
against the data schedule and battery manufacturer's requirements. An accurate voltmeter
should be used to measure the voltage at the output terminals of the battery charger and then
across the positive and negative terminals of the battery. The difference of these two voltages
will indicate the voltage drop of the battery charger input circuit. This voltage drop should be
minimal.
The voltage output of the battery charger must checked to verify that the charger voltage will
be regulated within the specified limits listed on the data schedule. A guide for the percent
voltage regulation requirements is provided below.
Battery Charger Size Float Operation Mode Recharge (Equalize) Operation

Mode
< 10 kW +/- 1% +/- 2%
> 10 kW +/- 1% +/- 1%

BATTERY AND BATTERY CHARGER SYSTEM OPERATIONAL TESTING

REQUIREMENTS
The battery charger should be tested to ensure that the battery charger is capable of delivering
the specified current output to the battery for the specified time as indicated on the data
schedule. The battery should be load tested to confirm that it will deliver the specified value
of current to the load for the specified length of time without reaching the final discharge
voltage. These tests are best accomplished through use of a load bank of sufficient rating.
The float and equalize settings should be verified, and the actual value of these settings should
be measured under various conditions of charge rate and load. When the charger is operated
within the specified current capability, the charger voltage regulation should maintain output
voltage under all conditions.
Charging Rate
The charging rate of the battery charger can be verified by connecting the charger to the load
bank and adjusting the load to a value that will cause the charger to deliver the specified
output current. The charging rate verification test should be run for the length of time that is
required on the data schedule. During this test, the battery charger output voltage should be
continuously monitored to ensure that it is maintained within the specified limits.
Discharge Rate
The battery must be tested for its ability to discharge into the load and provide the rated value
of current for the specified length of time without reaching the final voltage. This test is
accomplished through use of a load bank. The battery output is connected to the load bank,
and the load bank is adjusted to cause the battery discharge current to equal the discharge
capability that is listed on the data schedule. An accurate voltmeter should be connected to
the battery output so that voltage readings can be monitored and recorded at regular intervals
during the test.
Float/Equalize Settings
After all the charger and battery testing is complete, a final check of the float setting and the
equalize setting should be confirmed. The float and equalize settings should provide a
constant voltage output through battery cycles of charging and discharging.

Charging Capacity (Amp-Hour Rating)
The battery charger ampere output is listed on the nameplate, and it can be calculated through
use of the following formula
A = ( SF * L + (BIF * AH/RT) ) /Kt
Where: A = Ampere rating of the charger.

SF = Service factor: 1.1.
L = Sum of continuous dc loads (amperes).
BIF = Battery inefficiency factor: 1.15 for lead-acid batteries and 1.14
for Ni-Cad batteries.
AH = Battery ampere-hour.
RT = Recharge time.
Kt = Temperature compensation:
Kt = 1.00 at or below 40_C.
Kt = 0.83 from 40_C to 50_C.
This rating of the battery charger is verified during the charger charging rate verification that
was described above.

REQUIREMENTS FOR THE SYSTEM OPERATIONAL OBSERVATION PHASE
After all tests and inspections of the battery system have been completed, and after the
commissioning process has resulted in the battery being placed in service, the battery system
should be monitored at frequent intervals for several weeks. The purpose of this observation
phase is to carefully monitor the battery and charger under all conditions of service for any
signs of improper or erratic operation.
The items that should be observed include all parts of the battery system. The charger output
should be monitored by observing and recording the output voltage and current. The charger
wiring should be inspected to note any signs of poor connections, overheating, or other
similar problems.
The battery should be observed for any signs of cell overheating, excessive loss of electrolyte,
leaking cell jars, and loose battery connections.
Specific gravity tests should be conducted and recorded after the battery has been in normal
service for a period of time. The specific gravity of all cells should be within a small
percentage of each other.
If ac power is lost to the battery charger, the battery will be the sole source of dc power.
When a loss of ac power occurs, the battery voltage and discharge rate should be noted.

SUMMARY
As mentioned in the Introduction, commissioning of batteries and battery charger systems is

part of the overall process by which a facility is commissioned. The actions explained below
are required to bring commissioning of batteries and battery chargers to completion.
After the battery has completed the testing and operational observance phase, after all items
have been verified as satisfactory, the battery system should be accepted as having completed
the commissioning process. Maintenance intervals should be established so that all
components of the battery system that require routine maintenance are placed on a periodic
maintenance schedule.
All the commissioning documents, including data schedules, commissioning form P-003,
manufacturers' technical manuals, system drawings, and any other related paperwork should
be turned over to the appropriate authority for proper custody.
A spare parts inventory should be maintained that is based on the charger and battery
manufacturer's recommendations. This spare parts inventory would include items, such as
spare hardware for the battery intercell connectors, battery rack hardware, and spare parts for
the charger internal circuits.
Battery rooms receive a final inspection to ensure that all the items, such as the ventilation or
air conditioning system and eyewash and shower facilities, function properly. The inspection
should include verification that all the accessories that are necessary to maintain the battery
are properly located in the battery room.

WORK AID 1: REFERENCES FOR EVALUATING BATTERIES AND BATTERY

CHARGERS UPON RECEIPT
The following information is to be used as a guide for performing Exercise 1. The
information that is provided should be used in addition to the Saudi Aramco Battery Pre-
Commissioning Form P-003, sheets 1 through 4. (This form is obtained from the
Instrumentation unit of the Consulting Services Department.)
Criteria for Evaluating Batteries Upon Receipt
1. Verify that the battery cells are of the type that is indicated on the data schedule. The type
of battery should be one of the following:
• Ni-Cad (pocket-plate)
• Plante
• Lead-Calcium
• Lead-Antimony (maximum 3% antimony)
• Tubular Lead (maximum 3% antimony)
Note: Ni-Cad cells must be of the vented pocket-plate construction. Sintered-plate

cells are not permitted.
2. Verify that the recharge period is as specified on the data sheet.
3. Verify that the number of cells corresponds to the battery nominal voltage.
Nominal Battery
System Voltage Number of Cells
(vdc)
Lead-Acid Ni-Cad
12 6 10
24 12 19
48 24 37
120/125 60 92
240/250 120 184
360/375 180 276
4. Verify that the battery manufacturer's design float voltage is as indicated on the data
schedule.
5. Verify that the maintenance interval is as indicated on the data schedule, both standard
and extended.
6. Verify that the battery design ambient temperature is in accordance with the data schedule.

7. Verify that the electrolyte density corresponds to the data schedule.
8. Verify that the battery load is per the data schedule information or that the battery will
accommodate the load profile that is attached to the data schedule.
Criteria for Evaluating Battery Chargers Upon Receipt
1. The battery charger's nameplate data should be verified against the data schedule through
comparison of the nameplate data to the following information that is indicated on the data
schedule.
AC Input
Nominal Voltage = or - 10% phases
Frequency 60 Hz + or - 5 %
Available short-circuit current rms symmetrical amperes
Battery Load
Type: Ni-Cad
Lead Calcium
Plante
Lead-Antimony
Charging capacity for hours to final volts per cell.
External dc load (excluding battery)
Amperes Maximum
Duty Cycle Description
Output Voltage Range
Floating volts minimum to volts maximum

Equalizing volts minimum to volts maximum
Ambient Temperature
Maximum

Minimum
2. The battery chargers for Saudi Aramco dc systems should be constant-potential, semi-
conductor, static-type chargers that are designed to simultaneously supply dc power to a
float-type battery and to the connected dc loads. The battery charger that is received
should be one of the two types that are listed below as specified on the material data sheet:
• Static Plate Rectifier

• Solid State Rectifier
3. Verify that the battery charger meets the requirements of NEMA PE 5-1983 with the
additions and exceptions that are listed in 17-SAMSS-514. The following information
should be as specified on the data schedule and is an exception to NEMA PE 5-1985:
"Input supply voltage and frequency are as specified on the data schedule."
4. The following items are in addition to the requirements of NEMA PE 5-1985:
• Panel meters that are furnished on the battery charger must have an accuracy of +/- 2%
of full scale accuracy, and designed in accordance with ANSI C39.1. Each battery
charger must be supplied with a dc ammeter and voltmeter.
• Printed circuit boards that are contained within the battery charger must meet the
requirements of UL 796 and several additional requirements as listed in 17-SAMSS-
514.
• The battery charger must be equipped with an end of discharge relay that operates
when the battery discharges to a voltage of 1.75 volts for lead-acid cells and 1.10 volts
for Ni-Cad cells.
• The charger should come equipped with a ground detection relay for the dc bus that is
capable of detecting grounds on either the positive or negative bus.
• Battery charger alarm relays must have form "C" single-pole, double-throw relay
contacts.
• The battery charger output voltage regulation must be designed to maintain voltage
regulation when the battery is disconnected from the charger (battery elimination
feature).
• The battery charger is equipped with a filter that meets "limit B" requirements for
output ripple.

• The battery charger must be equipped with an input circuit breaker that has an
interrupting rating that is equal to or greater than the available short-circuit currents
that are listed on the data schedule (14,000 rms symmetrical amps minimum). This
requirement may be alternately met through use of current limiting fuses of the
required interrupting rating. The circuit breaker must be designed and tested in
accordance with UL 489.
• The charger must be equipped with an output breaker or disconnect switch that will
simultaneously open both output lines.
Enclosures for the battery charger must meet the following requirements:
• Enclosures must be either carbon steel or aluminum, and they must meet the
requirements of NEMA ICS 6, Type 1.
• Enclosures must be naturally or force ventilated. If the enclosure is force ventilated, it

must be equipped with removable, easily-cleaned air filters.
• The enclosure must be designed for front access to all components, and it must have
double or full-length, hinged doors.
• Handles, hinges, and screws must be corrosion resistant.
• Terminal blocks must be provided for connection to external alarm circuits and must
be of a phenolic, one-piece, barrier-type with pan head screws.
• Insulated compression-type terminals must be provided for all wiring that terminates
on terminal blocks. Solder terminals are not permitted for connection to terminal
blocks.
• Power cable terminations (lugs) must be the copper-bodied, compression-type

(crimped-type) that are suitable for use with ASTM Class B and C stranded
conductors.
• All wiring must be stranded copper conductors only.
• Wiring terminal blocks must be identified with thermoplastic slip-on wire markers
with permanently printed characters. The wiring markers must directly correspond to
the numbering found on the schematic.
• Nameplates on the charger must be written in the English language.

• Exterior nameplates are to be attached with stainless steel or brass screws, and internal
compartment nameplates may be attached with permanent adhesive. All devices that
are located within a panel must be identified with a suitable nameplate that identifies
the item and its function.
The following accessory devices must be provided on the battery charger:
• Equalizing timer
• Low voltage alarm relay
• Overvoltage alarm relay
• Charger failure relay
• Low current alarm relay
Physical Inspection
The battery, battery charger, and associated equipment should be physically inspected for the
following:
• Lead-acid cells are shipped in a "dry-charged" condition. Each cell should be

sealed with a moisture-proof vent cap. Ni-Cad cells should be shipped dry,
discharged, and sealed with moisture-proof vent caps.
• Individual cells should arrive wrapped and sealed against moisture with a
desiccant. There should be instructions contained in each cell shipping container
that instructs how to correctly lift the cell.
• The shipping information sheet should indicate that the cells should be stored in a
cool, dry location. The label on the outer wrapping of the cell should include the
manufacturer's warranty statement, which includes the storage conditions, date of
shipment, and maximum storage time from date of manufacture.
• The cell accessories should be included with each cell, and they should not be
shipped in bulk in a separate package.
• Battery plate material is of the type that is specified in the data schedule. The Ni-
Cad cells must be of the vented pocket-plate construction. Sintered-plate Ni-Cad
cells are not permitted to be used in Saudi Aramco battery systems.

• The battery containers should be constructed of a heat- and impact-resistant plastic

material that is either transparent or translucent. Adequate space must be provided
above the cells to meet the manufacturer's maintenance schedule. The cell jars
should also have clearly-marked level lines on the sides of the container.
• The cell cover and the container must be sealed properly at the joint between these
two parts, which provides a gas-tight seal.
• The cells should be equipped with explosion-proof vent caps that meet the
requirements of NEMA-IB-7. These vent caps are designed to allow gases to
escape from the cells, but they prevent any flame or sparks from entering the cell.
• The intercell connectors and battery cable terminals should be checked to ensure
they are of the proper size and material to carry the design current and not permit
excessive voltage drop. Ensure that the intercell connectors are of the correct type
for the particular battery. If copper links are used, they must be coated with a
homogeneous lead or lead alloy coating that is no less than 50 micrometers (0.002
in.) thick. If the battery is a Ni-Cad-type, the intercell connectors must be nickel
plated. Connector bolts, nuts, and washers must be either lead-plated brass or
stainless steel (ANSI type 316). The polarity of each cell terminal must be clearly
marked as positive or negative.
• Battery racks should be inspected and verified for the following conditions:
- The racks should be a one- or two-row stepped arrangement that is large

enough to accommodate the number of cells.
- The racks should be no more than two tiers in height.
- The width of the racks must be at least as wide as the battery cell width.
- The racks should be constructed of welded structural steel frames with bolted-
on steel runners and braces and with provision for anchoring the racks to the
floor.
- The metal frame of the racks should be coated with an acid-resistant plastic or
equivalent material.
• Additionally, a sufficient quality of the battery rack coating material should be

supplied by the vendor to take care of nicks and to cover exposed hardware and
bolt threads after the racks have been installed.
• A verification of the required accessories should include:

- Battery cell thermometer
- Hydrometer with temperature correction scale (for lead-acid cells)
- Insulated wrenches to fit battery hardware
- Bottle with pour spout for adding distilled water
- Spare intercell connecting hardware and extra rack bolts and nuts that are equal
to 10% of the total hardware
- Supply of NO-OX terminal grease (lead-acid only)
- Cell lifting straps or apparatus for cells over 34Kg (75lb)
- Cell voltmeter
All components must be inspected for any visual signs of damage or deterioration during
shipment. This inspection should include items that are broken, bent, cracked, or other
obvious signs of damage. All of the battery cell containers must also be checked. Any effects
of corrosion or moisture damage that often occur during shipping should also be noted.
Saudi Aramco Pre-Commissioning Form P-003, Battery System
The Saudi Aramco Pre-Commissioning Form P-003, Battery System, provides a field
installation checklist for batteries and battery chargers. The pre-commissioning form has a
broad checklist of visual and mechanical inspections, as well as the listed electrical tests that
are required for battery and battery charger installations. Space is also provided on the form
for test data. This form is obtained from the Instrumentation Unit of the Consulting Services
Department.

Saudi Aramco Pre-Commissioning Form, P-003, Battery System

Figure 22


Figure 22 (Cont'd)


Figure 22 (Cont'd)


Figure 22 (Cont'd)
WORK AID 2: REFERENCES FOR EVALUATING BATTERY AND BATTERY

CHARGER INSTALLATION AND TESTING
The Participant should use Work Aid 2 as necessary to complete Exercise 2.
Procedure for Evaluating Battery and Battery Charger Installation and Testing
1. Verify that the battery and battery rack have been installed correctly. Inspect for proper
equipment grounding of battery rack, battery charger enclosure, and all non-current-
carrying metal parts of the system. Ensure that these components are properly connected
to the equipment grounding circuit. Ensure that all parts of the battery rack have been
painted with appropriate coating after installation of all rack hardware.
2. Eyewash and Shower Stations
2a. The eyewash and shower stations may be equipped with an alarm that is activated
whenever either facility is operated. The determination of an alarm is made by the
Industrial Hygiene Unit of the Medical Services. If an alarm is installed, verify that it
operates correctly by operating the eyewash and the emergency shower.
2b. During the commissioning of battery systems, the installation of showers and eyewash
stations should be carefully inspected to ensure that they meet the requirements of
SAES-B-069 and that they function properly.
2c. Verify that the eyewash and shower can provide a continuous flow rate for at least 15
minutes at a pressure that is no greater than 207 kPa (30 psig) and at a temperature that
is no greater than 37.8_C (100_F) except for the short period of time where water is
naturally heated from the environment by above-ground piping. If the system is
capable of delivering higher pressure at the eyewash and shower outlets, the pressure

must be maintained through use of pressure controllers or self-regulating orifices to

prevent the pressure from exceeding 207 kPa.
3. Verify that all accessory equipment is in place, including:
• Safety protective clothing

• Hydrometer (for lead-acid cells)
• Cell voltmeter
• Cell thermometer
• Insulated wrenches to fit battery hardware
• Bottle with pour spout for battery water
• Spare intercell connecting hardware, 10% of total amount
• Supply of NO-OX terminal grease (lead acid only)
• Cell lifting straps for cells over 34 kg (75 lb.)
4. Verify that the battery intercell connectors are properly torqued and that non-corrosive
protective coating has been applied to terminal connections.
5. Verify the battery charger operating conditions:
• Float voltage is between 2.25 volts to 2.30 volts per cell for lead-acid cells, or +/- 1.0
% of the nominal voltage, or as recommended by the battery manufacturer.
• Equalize voltage should be within +/- 1.0% of the specified equalize voltage that is
recommended by the battery manufacturer. If the battery charger is 10 kW or less, the
acceptable value is +/- 2 % of nominal voltage (cell open circuit voltage).
6. Battery Cells
6a. Verify that the battery cell terminal resistance has been measured and that no
cell has a resistance greater than 10% or 5 micro-ohms, whichever is greater over the
average of all the cell terminal resistances.
6b. Cell Specific Gravity (Lead-Acid Only)
After the battery has been fully charged with the freshening charge and allowed to
remain on float charge for no less than 72 hours, specific gravity readings can be
taken. The specific gravity readings should be corrected for temperature. For every
3°F (1.67°C) above 77°F (25°C), add one point (.001) to the specific gravity reading.
For every 3° (1.67°C) below 77°F (25°C), subtract one point (.001) from the
hydrometer reading.

The specific gravity readings should be such that no cell has a specific gravity that is
more than ten points (0.010) below the average of the specific gravity of all cells after
corrections for temperature have been made.
6c. Cell Voltage
The acceptable value for 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 Ni-Cad cells.
6d. Battery Discharge Rate
The acceptable value for battery discharge rate is that the battery meets the
requirements that are specified on the data schedule and that the battery is in
accordance with the battery manufacturer's specifications.
Unless 100% battery capacity is specified upon delivery, batteries may be less than
rated capacity when received from the manufacturer.
Verify the battery discharge duration by testing. This testing involves discharging the
battery at a pre-determined value of current (based on the battery rating) and
measuring the time it takes the battery to reach its final voltage per cell (1.75 volts for
lead-acid) times the number of cells.
7. Check and Verify the Following Battery Charger Setpoints:
7a. End of charge condition alarm is +/- 5% of the 1.75 volts per cell for lead-acid cells
and +/- 5% of the 1.10 volts per cell for Ni-Cad cells.
7b. Low charger output voltage alarm setpoint is 2.2 volts per cell for lead-acid cells and
1.4 volts per cell for Ni-Cad cells.
7c. Ground detection alarm operates when the leakage current exceeds 10.0 milliamps,
which is a fixed value that is set by the equipment manufacturer.
7d. The charger overvoltage alarm setpoint should operate at +/- 10% of the nominal cell
voltage, as recommended by the charger manufacturer.
7e. The enclosure overtemperature alarm is + 10% , - 0% of the manufacturer's stated

operating temperature.

8. Inspect the battery room door and ensure that it opens outward and away from the
batteries to facilitate easy exit in the event of an emergency.
9. Verify that battery cables are installed in accordance with the NEC NFPA 70. Battery
cables should be installed neatly and properly. Verify that the cable AWG size and
insulation are in accordance with the ampacity of the battery system.
10. The battery output circuit breaker should be equipped with a low voltage shunt trip device
that will cause the circuit breaker to open if the battery voltage drops to a value 5% below
the battery final voltage. This circuit breaker undervoltage device should be tested to
confirm that it operates properly.

GLOSSARY
battery One or more electrochemical cells that are lined together to

provide a direct current output. Several cells are normally
connected in series to provide the desired nominal voltage of a
dc system.
battery charger An electrical device that is designed to convert an ac input to a

DC output for the purpose of charging electrochemical cells.
cell A container that is constructed to house the active plates and

electrolyte solution that are necessary to maintain an
electrochemical reaction that delivers direct current at its
terminals.
cell voltage The voltage that is measured at the terminals of an

electrochemical cell. The cell voltage can be an indication of the
state of charge of some types of cells.
cycle service A duty cycle that is characterized by frequent and usually deep
discharge sequences, such as motive power applications.
electrolyte A liquid mixture that is used in electrochemical cells to conduct

the migration of charges between the plates of the cells. The
electrolyte for lead-acid cells consists of a solution of sulfuric
acid and water; the electrolyte for Ni-Cad cells consists of a
solution of potassium hydroxide and water.
energy density A ratio of the energy that is available from a battery or cell to its
volume (Wh/L) or weight (Wh/kg).
equalize charge An amount of charging voltage and current that are sufficient to
restore all the cells of a battery to an equal state of charge.
flame arrestor A device that is used to allow generated gases to escape from
electrochemical cells and to prevent a spark or flame from
entering the cell and possibly causing an explosion.
float service A method of maintaining a cell or battery in a charged condition

by continuous, long-term, constant voltage charging at a level
sufficient to balance self-discharge.

freshening charge The charge that is applied to a new battery after it has been
received and filled with electrolyte. Flooded-plate-types of
battery cells are typically shipped in a dry charged condition.
hydrometer A device that is used to measure the specific gravity of an

electrolyte in an electrochemical cell.
intercell connectors Rectangular metallic links that are designed to connect adjacent
cells to one another in a battery. These links are commonly
made of lead-plated copper for lead-acid cells or of stainless
steel for Ni-Cad cells.
memory effect A phenomenon in which a cell is operated in successive cycles to

the same but less than full depth of discharge. When a battery is
repeatedly cycled to less than full depth, it temporarily loses the
rest of its capacity at normal voltage levels. This phenomenon
normally applies to Ni-Cad cells only.
Plante cell A specific type of lead-acid cell in which the active materials are
formed directly from a lead substrate by electrochemical
processing. Cells of the Plante design provide long service life,
low positive plate growth, and very high reliability when
compared to other types of lead-acid cells.
power density The ratio of the power that is available from a battery or cell to
its weight (W/kg) or volume (W/L).
specific gravity The ratio of the weight of an electrolyte solution compared to

water. For example, an electrolyte solution that has a specific
gravity of 1.215 has 1.215 times the density of water. The
specific gravity is an indication of the state of charge of certain
types of electrochemical cells, such as lead-acid cells.
VPC (voltage per cell) This term is used to indicate the average voltage that is available
at the terminals of an individual cell. VPC may be determined
by dividing the total battery voltage by the number of cells in the
battery.

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

Chapter : Electrical For additional information on this subject, contact

Saudi Aramco Applications And Requirements For Batteries

And Battery Charger System............................................................................ 1

Evaluating Battery And Battery Charger Systems Upon Receipt .................... 36

Evaluating Battery And Battery Charger Installation And Testing ................... 38

Battery And Battery Charger System Operational Testing Requirements ....... 43

Requirements For The System Operational Observation Phase .................... 45

Work Aid 1: References For Evaluating Batteries And Battery

Chargers Upon Receipt .................................................................................. 47

Work Aid 2: References For Evaluating Batteries And Battery

Charger Installation And Testing..................................................................... 58

Saudi Aramco DeskTop Standards

SAUDI ARAMCO APPLICATIONS AND REQUIREMENTS FOR BATTERIES AND

Saudi Aramco DeskTop Standards 1

Saudi Aramco DeskTop Standards 2

Basic Components of a Lead-Acid Cell

Saudi Aramco DeskTop Standards 3

Saudi Aramco DeskTop Standards 4

Saudi Aramco DeskTop Standards 5

Saudi Aramco DeskTop Standards 6

Positive Plates Used in Plante Lead-Acid Batteries

Saudi Aramco DeskTop Standards 7

Saudi Aramco DeskTop Standards 8

Typical Pasted Plate Grid

Saudi Aramco DeskTop Standards 9

density than Plante batteries. discharges.

Saudi Aramco DeskTop Standards 10

Sealed (Maintenance-Free) - Two different versions of sealed (maintenance-free) lead-acid

Saudi Aramco DeskTop Standards 11

Nickel Cadmium (Ni-Cad)

Saudi Aramco DeskTop Standards 12

Saudi Aramco DeskTop Standards 13

• Vent Cap/Flame Arrestor

Saudi Aramco DeskTop Standards 14

Typical Pocket-Plate Ni-Cad Battery

Saudi Aramco DeskTop Standards 15

Saudi Aramco DeskTop Standards 16

Sintered-plate Ni-Cad batteries are constructed similarly to pocket-plate Ni-Cad batteries.

Saudi Aramco DeskTop Standards 17

Saudi Aramco DeskTop Standards 18

Typical Sintered-Plate Ni-Cad Battery

Saudi Aramco DeskTop Standards 19

Advantages and Disadvantages of Sintered-Plate Ni-Cad Batteries

Saudi Aramco DeskTop Standards 20

Nominal System Voltage Minimum System Voltage Maximum System Voltage

Saudi Aramco DeskTop Standards 21

Saudi Aramco DeskTop Standards 22

• L1 represents 50 amps of continuous emergency lighting load for three hours.

Saudi Aramco DeskTop Standards 23

• L5 represents 50 amps of momentary switchgear operations load that occurs during

Saudi Aramco DeskTop Standards 24

Duty Cycle Diagram

Saudi Aramco DeskTop Standards 25

where: L = one-way length of the circuit to the farthest point

R = dc resistance of the conductor per 1000 linear feet

I = maximum expected continuous load current to the load

• Static Plate Rectifier

Saudi Aramco DeskTop Standards 26

Static Plate Rectifier

Saudi Aramco DeskTop Standards 27

Static Plate Rectifier