STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

NTPC REF NO: SIM/ 1/ TS/ 1 /112

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

SHEET 1 OF 15

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 2 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT

1.0 PLANT DETAILS

This system consists of:
i.

Battery Bank

ii.

Battery Charger - Main and Standby

iii.

DC Distribution board.
The battery is installed in the battery room in the HT switchgear room. This
provides a 220 V DC supply to the relay and control circuits in the Generator.
Generator transformer and Unit transformer protection and control panels, 11KV
and 3.3 KV HT switchgear and 4.5 V LT switchgears Unit and station service
boards and aux. Control panels.

Battery Cells - Data Sheet

Guaranteed AH Capacity at 10 Hrs.discharge
Rate 1 Volt / Cell at 27 C

990 AH

Designation

KPH 990 P

1.4 -- 1.42 V/Cell

Voltage

1.53 -- 1.67 V/Cell

Trickle charging current

1 to 2 MA /AH

Boost charging current

198 A

Recommended range of floating/trickle

Charging voltage
Recommended range of boost charging

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 3 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1/112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
Open circuit voltage of cell when completely
Discharged at 27 C at 5 hrs discharge rage

Dimension (mm)

1.0 V
-

522 L x 192 W x 405 H

Per cell required for first filling at 27 C

18 Lit / cell, 1.19 +- 0.01

Specific gravity of cell when fully charged

1.19+- 0.01

Continuously

50 C

Net dry cell weight

45 Kg

With electrolyte

68 Kg

Cell container material

Polypropylene

No of cells / Bank

169

Amount of specific gravity or electrolyte

Max. electrolyte temp. that cell can withstand

Charger - I & II
Input Voltage

415 V+- 10%

Output Voltage

220 V DC

Float Voltage

236 V DC

Boost Voltage

287.3 V DC

Rectifier current limit

400 A

Battery current limit

198 A

Auto charge over current

40 A

Steady state output voltage Regulation (For +- 10% I/P

Voltage variation
0 - 100 % load variation
at a time).

+-1%

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 4 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT

2.0 TESTING OBJECTIVES:

2.1 To ensure that all the relevant checklists have been completed for the battery,
battery charger and distribution boards.
2.2 To complete the connections between the battery / battery charger and the
distribution boards.
2.3 To make the distribution board live at 220 V DC in a safe and orderly manner.
2.4 To carry tests and checks to ensure that all the components on the borads are
operating satisfactorily including cables to all the remote points in the 400 KV
substation and control room.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112

SHEET 5 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 /112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT

3.0
3.1

TESTING PROPOSALS:
AC distribution board for 3 phase AC input supply to chargers will be made

live.
3.2

Each module will be checked individually.

3.3

Each outgoing supply will be tested up to the fuses at the remote end.

3.4

Battery E/F will be simulated for both the poles and E/F relay sensitivity will be
checked.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112

NTPC REF NO: SIM/ 1/ TS/ 1 /112
PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
4.0

SERVICES REQUIRED:

4.1

415 V, 3 Phases, 50 Hz supply.

4.2

Adequate running water.

4.3

Suitable voltmeter, ammeter, thermometer and hydrometer.

4.4

Variable resistance or water load for discharging the battery.

4.5

Electrolyte for cells as per IS-266

4.6

Pure battery grade distilled water.

4.7

Funnel, jugs, cleaning brush, wire brush etc.

4.8

Variable resistance box of 15 to 150 K Ohms

4.9

1 No. 500 VDC megger.

4.10

1 No. oscilloscope, preferably dual beam or dual trace.

4.11

1 No. AVO meter or multimeter 0 - 1000 V DC

4.12

1 No. phase rotation indicator.

SHEET 6 OF 15

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 7 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
5.0

SAFETY PRECAUTIONS:
The following equipment will be available at all times:

5.1

Eye wash bottle

5.2

Safety goggles.

5.3

Rubber gloves

5.4

Insulated spanners and tools

5.5

5% to 10% ammonia or soda solution.

5.6

Exhaust fan near ceiling.

5.7

Acid proof aprons.

PLANT:
5.8

Acid proof ashphault flooring battery room.

5.9

Fire extinguishers installed.

5.10

" NO SMOKING AND 'NAKED FLAME' notices should be displayed.

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 8 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
6.0

EMERGENCY PROCEDURE:

6.1

First aid charts for acid injuires and electrical shock will be displayed.

6.2

In case of any accident involving acid burns neutralizing solution must be

applied.
6.3

All the persons working on battery shall wear, acid proof aprons.

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
7.0

STATE OF THE PLANT:

7.1

Check list for the following plant item completed.

i.

Battery charger

ii.

DC distribution board.

7.2

All outgoing cabling work completed up to remote end panels.

7.3

All outgoing feeders from DC distribution board switched off.

7.4

Safety clearance certificates signed and returned by all parties.

SHEET 9 OF 15

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 10 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
8.0

COMMISSIONING PROCEDURE:

1.

TESTING OF BATTERY CHARGERS:

8.1

The insulation value shall be checked with 500 V DC Megger. During this test, all
low voltage circuits & Relays etc, shall be kept shorted.

8.2

The panel shall be switched on at no load. For this, first make input switch Q1 ON
& check the voltages at all phases indicated by lamps VD1, VD2 & VD# &
voltmeter by selector switch VS1. Now the voltage is connected to the primary of
the Main transformer which steps the voltage down as required for the specific DC
output Voltage & isolates AC Input line from Battery circuits. The transformer's
secondary is connected to the Full wave rectifier assembly.
The bridge is standard three phase full wave half controlled silicon bridge. The
voltage control is accomplished by the application of a positive pulse to the gate
terminals of the SCR at the desired time. Before the pulse is applied , the SCR is
open and no current flows in the circuit. As soon as SCR is fired, it operates as a
standard silicon rectifier until the forward current is reduced to almost zero.

8.3

Check the no load output voltage at the output terminals.

8.4

Ensure the output voltage is steady without any trouble for 15 minutes.

8.5

Check for annunciation interlocks etc.

STATION : NTPC SIMHADRI BHEL REF NO: PS-DC-186-500-112

SHEET 11 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
8.6

If load is available, the equipment shall be loaded progreesively upto rated value
Check for voltage regulation, free from oscillation, ripple etc.

8.7

Check for dropping characteristics at higher loads.

8.8

Run the equipment for 2 hours and observe of stability and check for local heating.
When unit is loaded the ripple voltage level (peak to peak) may be observed on a
CRO. This will be within limits. Incase, it is more than specified , then it means
firing is disturbed.

II

FIRST CHARGING OF BATTERY:

8.9

DC Voltage needed for battery charging will be 2 times the no of cells in battery
bank. The initial charging will take approximately 16 to 24 hours since the batteries
are already charged and sent as maintenance free ones.

8.10

It is of utmost importance that the terminal of the battery is connected to +ve load
of charging source. So polarity should be ascertained.

8.11

Check thoroughly to ensure cells are connected in series and all fastenings and
connections are tight. The test polarity of the charging leads and correct the +ve
terminal to that of charger.

8.12

Commence charging not later than 24 hours after connecting all battery cells.

8.13

Give the first portion of charge at a rate of 100 Amps for 10 Hours

8.14

Discharge it using Water resistance or halogen lamps at a rate of

8.15

Give the second charging at the rate of approximately 20 Amps till the signs of
completion of charge observed.

for hours.

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500- 112 SHEET 12 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1/ 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
8.16

Select any one cell (except the end cell or regulating cell) as pilot cell out of every
rack as given in the layout of the battery bank.

8.17

Voltage and specific gravity reading from pilot cells will indicate the state of
charging of the whole battery system.

8.18

All cell terminals & connections are to be applied with pertroleum jelly. No
adjustment should be made which will disturb charging.

8.19

When all the cells have been greasinyg freely and when voltage and specific gravity
of pilot cell has been constant over 3 successive hour readings, the cells can be
deemed to be fully charged and the charging may be terminated. Then wipe down
outside of all cells and clean the floor.

8.20

Put the battery system on trickle charging when charging completes.

CAUTION : DONT TOUCH BATTERY TERMINALS WHEN CLEANING OUTSIDE AND

BATTERY AREA. USE PROPER GLOVES AND OTHER SAFETY MATERIALS.
8.21

The trickle charge should be adjusted to give optimum battery voltage of 1.53 - 1.67
volts per cell.

III

ENERGISING OF DISTRIBUTION BOARD:

8.22

Take final I.R. value of the board

8.23

Ensure that all outgoing circuits are locked in OFF position.

8.24

Ensure that all safety procedures have been observed.

8.25

Check that polarities of D.C switch board battery charger and battery are matching.

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 13 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1/ 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
8.26

Close the incomer switch of board to charge it.

8.27

Measure D.C Voltage at the Input.

8.28

Observe D.C board for any abnormality.

8.29

If board condition is satisfactory, check that all remote end fuses of outgoing
circuits are removed.

8.30

Switch ON outgoing feeders one by one. Record the following for each circuit.
i.)

Polarity at both ends of circuit

ii.)

Voltage at both ends of circuit.

IV

EARTHFAULT RELAY ON LOAD TEST:

8.31

To carry out on load test for the Battery E/F relay, connect variable resistance box
of the range of 15 to 150 K Ohms between +ve pole of the board and earth

8.32

Keep selectivity setting plug of E/F relay at 3 ms setting.

8.33

Cut out resistance slowly to simulate an E/F and observe the current in milli
ammeter when the relay operates.

8.34

Record resistance and current in mA

8.35

Carry out this test on each available setting on relay.

8.36

While doing test observe and record the direction of deflection in the ammeter.
Check whether it confirms the pole on which the fault is simulated.

8.37

Repeat 8.32 to 8.37 on -ve pole of the board

8.38

The test is satisfactory if the operation of the relay confirms with the setting

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 14 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1 / 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
9.COMPLETION CRITERIA:
220 V DC System for main plant is ready and All measurements and remote
indication points are recorded and kept along with this Schedule.

STATION : NTPC SIMHADRI

BHEL REF NO: PS-DC-186-500-112

SHEET 15 OF 15

NTPC REF NO: SIM/ 1/ TS/ 1/ 112

PLANT AREA: ELECTRICAL SYSTEM
TESTING SCHEDULE : 220 V DC SYSTEM FOR MAIN PLANT
10.APPENDICES
DRAWINGS: LAY OUT OF BATTERY ARRANGEMENT
SCHEMATIC DIAGRAM OF BATTERY CHARGERS
SCHEMATIC DIAGRAM OF DC DISTRIBUTION BOARD.

220 V DC SYSTEM FOR MAIN PLANT