The Battery Bank installation contains and commissioning mainly two types

  1. Replacing old battery bank by new batteries
  2. Installation and commissioning of complete new Batteries.

For the first type you have total infra structure ready i.e. Battery Room, Battery Charger, Battery Stand and Cabling from Charger to Battery and from Battery to Load,

In the second type, you will have to Design / Select all above mentioned things as per Battery Bank Capacity

In first case, the total infrastructure is ready and you have replace the Old Batteries by New ones of same capacity. For carrying out this work following steps are involved.

  1. As the Battery is already connected to Charger and Load, you will have to shift the Load to another available Charger / Battery in the system such that Battery should be isolated from load.
  2. Switch off the Charger connected to Battery.
  3. Remove all cables, inter-cell, inter-row connectors.
  4. Drain the electrolyte and store it safely and (While draining the electrolyte proper care should be taken) Shift the old batteries to safe place.
  5. Assemble new batteries on the Battery stand. While placing batteries on stand polarity of batteries should be confirmed.
  6. Fill the battery electrolyte of specific gravity 1185 up to filling level on the battery container.
  7. Allow batteries to soak acid for minimum Eight (8) Hours.
  8. Meanwhile connect the inter cell connectors & charger to battery cables. Make battery bank ready for initial charging.
  9. Start initial charging at the starting rate of Current equivalent to 10% of battery capacity i.e. for 100 AH battery the initial charging current should be 10Amps. The initial charge should be given for minimum six times the battery capacity i.e. for 100AH battery minimum 600 AH of charging should be done.
  10. Continue the charging at starting rate till cell voltage reaches 2.35V to 2.45V.
  11. Take hourly reading of cell voltage, specific gravity and temperature.
  12. Once cell voltage reaches 2.35V to 2.45V, reduce charging current to finishing rate ( Finishing rate is 5% battery capacity) and continue the charging. Ensure that total AH input remains same.
  13. In the process of charging cell temperature should not exceed 40 degree centigrade. If it exceeds, stop the charging. Allow temperature to come down to 30 degree centigrade and continue charging at finishing rate. Ensure that the total AH input is maintained.
  14. Cells are considered fully charged once the three consecutive hourly reading of cell voltage and electrolyte specific gravity is found to be constant that is above 1200.
  15. Keep batteries idle for 4 Hrs.
  16. Make preparation for battery discharging. During discharging isolate battery from charger.
  17. Battery discharging can be done by means of water load or resistive load which ever is available/suitable.
  18. Discharge batteries at C-5 or c 10 rate which ever is suitable.
  19. Record Specific gravity and cell voltage and temperature of all cells.
  20. Stop discharging after 5 hours (if discharging at C5 rate) or average cell voltage reaches 1.82V per cell which ever is earlier.
  21. Recharge the battery bank; follow steps 9 to 14. Record Specific gravity and cell voltages and temperature of all cells during recharging.
  22. Follow the steps 16 to 20 for second discharge cycle.
  23. If specific gravity of some of the cells is found below 1200 during second discharging, adjust the specific gravity by adding concentrated electrolyte.
  24. For recharging, keep batteries on float charging the battery bank i.e. final charging; follow steps 9 &14. Record Specific gravity and cell voltages of all cells during recharging.
  25. After completion of procedure keep batteries on float charging.
  26. This process of new battery installation and commissioning takes about six to seven days

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