ELE Std. Check List VOL-1

7/28/2019 ELE Std. Check List VOL-1

1/53

STANDARD C HECK LIST

ELECTRICAL

VOLUME 1

CONTENTS

SL.NO. T I T L E SCL REF. NO

SECTION A

1. 220 KV / 400 KV CL/SS TRANSFORMER E.1.1

2. 33/15.75 KV & 11 KV TRANSFORMER E.1.2

3. 6.6 KV / 415 V TRANSFORMER E.1.3

SECTION B

1. D.C. BATTERY (ANY VOLTAGE) E.4.1

2. D.C BATTERY CHARGER E.4.2

3. D.C BOARDS E.4.3


2/53

S E C T I O N - A


3/53

ELECTRICALSTATION : STANDARD CHECKLIST SHEET 1 OF 4

PLANT ITEM : 400 KV CLASS TRANSFORMER REF: NO.: E.1.

SUPPLIER _____________________________________________________________

MANUFACTURER ___________________________ SRL.NO. ___________________

IDENTIFICATION _________________________________________________

LOCATION ______________________________________________________

RATING ________________________________________________________

REMARKS:NTPCSIGNATURE

BHELSIGNATURE

DATE:


4/53


PLANT ITEM : 400 KV CLASS TRANSFORMER REF: NO.: E.1.

NO

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

GENERAL INSPECTION AND CHECKS.

Ensure that erection work of the transformer and associated equipmentsare completed in all respect.

Check that no part of transformer and associated equipment is damaged.

Ensure safe and satisfactory access to the equipments.

Ensure that oil drainage system is complete and connected to oil pit.

Check that permanent and adequate lighting arrangements are made.

Ensure fire protection system is adequate.

Check that painting work is satisfactory.

Check that labeling and identification is permanent and satisfactory.

Check up for adequate clearances form the foundation to the valvefittings, marshalling box, tap changer handle and ensure proper workingfacilities are available.

Check that all external fittings are as per the external arrangementdrawings of manufacturer.

Carefully examine the transformer for oil leaks from all gaskets joints,valves, buchholz relay air release cocks etc.


BHELSIGNATURE

DATE:


5/53


PLANT ITEM : 400 KV CLASS TRANSFORMER REF: NO.: E.1.NO

1.0

1.12

1.13

1.14

1.15

1.16

1.17

1.18

1.19

1.20

GENERAL INSPECTIONS AND CHECKS.

Ensure correct oil level in the following:

a. conservator.b. H.V. bushingc. L.V. bushing (at the time of erection).

Check N 2 gas pressure on top of expansion chamber of H.V. bushing.

H.V. / L.V. bushings and other insulators for any crack.

Check that buchholz relay is correctly mounted with arrow pointingtowards conservator.

Check that pressure relief valve is correctly mounted.

Check that air has been released from the following points:

a. Radiators and their headers.b. Buchholz relay.c. Main tank.

Ensure that all power cables are secured in their position tightly andcorrectly.

Ensure that all instruments mounted in marshalling box are calibratedobtain test report.

Check that power and control cables entering and leaving marshallingbox and cooler fan control panel are correctly glanded.

REMERKS:NTPCSIGNATURE

BHELSIGNATURE

DATE:


6/53


PLANT ITEM : 400 KV CLASS TRANSFORMER REF: NO.: E.1.NO

1.0

1.21

1.22

1.23

1.24

1.25

1.26

GENERAL INSPECTIONS AND CHECKS

Check wiring of fan control panel as per the relevant drawing and obtaintest certificate for thermal overload relays used for fan motor control.

Check I.R. valve of power and control circuit of fans. By a 500 V megger.

Ensure that the following points are effectively earthed and connected toearth grid:

a. Main tank (two points)

b. Marshalling box.c. H.V. neutral (through NGT if any).d. Control cubiclee. Each cooling fanf. Radiator banks.

Ensure that protection shields are provided on fans.

Check that silica gel breather is installed correctly and silica gel colour isblue.

Ensure that the H.V. bushing current transformer W.T.I currenttransformer is tested during erection, obtain test report.

REMERKS:NTPCSIGNATURE

BHELSIGNATURE

DATE:


7/53


8/53


PLANT ITEM : 400 KV CLASS TRANSFORMER REF: NO.: E.1.1

2.0 TEST PROCEDURE

Tag No.

HVVOLTS L.V. VOLTS

H.V.MAGCURRENT

A-NA-N

B-NB-C

C-NC-A a-n b-n c-n a-b b-c c-a A B C

1

2

3

5

6

2.5 VECTOR GROUP TEST:

A 415 volts 3-phase supply connected to HV terminals with normal earth connectionof star point removed. A-a connected together.

Bet Volts Bet-ween

Volts Bet-ween

Volts Bet-ween

Volts Bet-ween

Volts

A-b A-a B-a C-a a-bB-C A-b B-b C-b b-cC-A A-c B-C C-a c-a


BHELSIGNATURE

DATE:

ELECTRICAL


9/53

STATION : STANDARD CHECKLIST SHEET 3 OF 6PLANT ITEM : 400 KV CLASS TRANSFORMER REF: NO.: E.1.1NO2.0

2.5

2.7

TEST PROCEDURE

Magnetic balance test (On Nominal Tap):

Apply single phase L.V. in one phase and record voltages in the other two phases.

A - BB CC Aa - bb cc a

OIL TESTS:

Oil samples from top and bottom of tank, also tap change compartments.These will be taken in an approved manner to prevent oil being in contactwith atmospheres.


BHELSIGNATURE

DATE:

ELECTRICAL

DATE SAMPLING POINT ELECTRIC STRENGTH


10/53


2.8

2.9

TEST PROCEDURE

OIL TEST

BUCHHOLZ DEVICE :

Manufacturer _____________________Type ____________________ Inclination L Longitudinal (3 deg 7deg ) _________________________

Lateral (0deg 5deg)__________________

Quantity of air to operateAlarm contacts :___________________________ Trip contacts :___________________________ \cmdeg2

Approx. minimum air pressure to operate surgeContacts and type of equipment used____________________________

Winding temperature indicators, Test WTI by heatingBulb.

Trip operates at :______________________deg C.Alarm operates at :_____________________deg C.


BHELSIGNATURE

DATE:

DATE Sampling Moisture Acidity FlushPoint Content p.p.m. Point


11/53


PLANT ITEM : 400 KV CLASS TRANSFORMER REF: NO.: E.1.1NO

2.0 TEST PROCEDURE

SHORT CIRCUIT TEST

Short L.V. terminals and apply 3-phase, 415 V A-cSupply to HV. winding from a suitable source.Insert an ammeter is each phase. Adjust currenthighest value attainable, but not more than 10 Amps.Check current for each phase on all tap positions.The ammeter readings shall not deviate by more than a few mill-amps.form the set value during tap changing operation.


BHELSIGNATURE

DATE:

ELECTRICAL

TAP H.V. VOLTS L.V. CURRENT REMAKRS

R Y Y- B B R R Y B


12/53


2.11

2.11.1

2.11.2

2.11.3

2.11.4

TEST PROCEDURE

TEMPERATURE INDICATORS:

Calibrate dial temperature indicator bulb for oil temperature by hot bathand standard thermometer:

Winding temperature indicators:

Manufacturer: ___________________ Srl.No. ________________ Associated transformer winding :

Contact A - Alarm : __________________ deg C.

Setting B - Trip : __________________ deg C.C.T. Ratio (Amps) : __________________ .Ratio confirmed by : __________________ .Primary injection : __________________ .Heater coil resistance : __________________ .

Check alarm contacts operate alarm relay.

Check trip contacts operate flag relay and trip relay.

REMARKS:NTPC

SIGNATURE

BHEL

SIGNATURE

DATE:

ELECTRICAL


13/53

STATION : STANDARD CHECKLIST SHEET 1 OF 12PLANT ITEM : 33/6.6 KV & 15.75/6.6 KV TRANSFORMER REF: NO.: E.1.2

SUPPLIER _____________________________________________________________

MANUFACTURER ___________________________ SRL.NO. ___________________

RATING _________________ MVA _____________ VOLTS ________MAS

VECTOR GROUP __________________ TYPE OF COOLING USED ________

TYPE OF TAP CHANGER USED _____________________________________

IDENTIFICATION _________________________________________________

LOCATION ______________________________________________________

REMARKS:

NTPCSIGNATURE BHELSIGNATURE DATE:

ELECTRICAL


14/53

STATION : STANDARD CHECKLIST SHEET 2 OF 12PLANT ITEM : 33/6.6 KV & 15.75/6.6 KV TRANSFORMER REF: NO.: E.1.2ITEM

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

GENERAL INSPECTION AND CHECKS

Ensure that erection work of the transformer and associated equipmentsare complete in all respects.

Check that no part of transformer and associated equipment is damaged.

Ensure safe and satisfactory access to the equipments.

Ensure that oil drainage system is complete.

Check that permanent and adequate lighting arrangements are made.

Ensure fire protection system is adequate.

Check that painting work is satisfactory.

Check that labeling and identification is permanent and satisfactory.

Check up for adequate clearances from the foundation to valve fittings,marshalling box, tap changer handle and ensure proper working facilitiesare available.

Check that all external fittings are as per the external arrangementdrawings of the manufacturer.


BHELSIGNATURE

DATE:


15/53


PLANT ITEM : 33/6.6 KV & 15.75/6.6 KV TRANSFORMER REF: NO.: E.1.2NO

1.0

1.11

1.12

1.13

1.14

1.15

GENERALO INSPECTION AND CHECKS

Carefully examine the transformer for oil leaks from all gasket joints,valves, buchholz relay air release cocks etc.

Check that air has been released from all points of the oil circuit as per manufacturers re-commendations.

Check that oil levels are correct in conservator, bushings and all oil filledchambers.

Ensure that the following valves are kept closed.

a. Filter valves of transformer and load tap changer.b. Drain valves of transformer and load tap changer.c. Oil sampling valves, plugs of the main tank and load tap changer.d. The conservator top filling holes and drain valves.

Following valves are to be kept open for service conditions.

a. Radiator valves both bottom and top.

b. Conservator to tank connecting valves.

c. Conservator to load tap changer connecting valve.

d. Valve in the Equalizer pipe connection between explosion vent andconservator top.


BHELSIGNATURE

DATE:


16/53


PLANT ITEM : 33/6.6 KV & 15.75/6.6 KV TRANSFORMER REF: NO.: E.1.2NO1.0

1.16

1.17

1.18

1.19

1.20

1.21

1.22

1.23

GENERAL INSPECTIONS AND CHECKS

Check bushings are not damaged.

Check buchholz relay is correctly mounted with arrow pointing towardsconservator.

Ensure all cables are secured tightly and carefully.

Check that all cables are secured tightly and carefully.

Check that all equipment in marshalling box are undamaged, properly

mounted and as per the schedule.

Check that cables in marshalling box are correctly glanded andterminated and check wiring is in accordance with relevant drawings.

Check that all equipment in control cubicle are undamaged, properlymounted and as per the schedule.

Check that cables in control cubicle are correctly glanded and terminatedand check wiring is in accordance with the relevant drawings.


BHELSIGNATURE

DATE:


17/53


18/53


1.0

1.30

1.31

1.32

GENERAL INSTECTION AND CHECKS

Check N.G.R. is correctly and securely mounted and undamaged.

Check resistance of N.G.R and compare it with specified value.

Resistance:

Amb. Temperature.

Check connections from transformer neutral to N.G.R. and from N.G.R. tostation Earth System are satisfactory.


BHELSIGNATURE

DATE:

ELECTRICAL


19/53


2.0

2.1

2.2

TEST PROCEDURE

Take oil samples from top and bottom of tank and from any other oil filledchamber. These oil samples will be taken in an approved manner toprevent oil being in contact with atmosphere.

OIL TEST:

With transformer disconnected from HV & LV sides and equipmentcompletely isolated carry out IR test on the following :

Megger Used : __________________ KV Ambient Temperature : _________________ deg CH.V. Terminal to Tank :

i. : ________________ ii. : ________________

iii. : ________________


BHELSIGNATURE

DATE:

Date Sampling Electric Moisture Acidity FlashPoint Strength P.P.M. Point


20/53



2.0

2.3

2.4

TEST PROCEDURE

L.V. Terminal to tank :

i. : _________________ ii. : _________________ iii. : _________________

H.V. TO L.V. : _________________

Carry out D.C. winding resistance test:

H.V. Winding : _________________________ L. V. Winding : _________________________

RATIO AND MAGNETISING CURRENT TEST:

Carry out the radio and magnetizing current tests by connecting a threephase low voltage supply to H.V. Terminals with normal earth connectionof the star point removed. At the same time measure the H.V.magnetizing current at the minimum, normal and max. tap positions.


BHELSIGNATURE

DATE:


21/53



2.0 TEST PROCEDURE

TAP H.V. VOLTS L.V. VOLTS H.V.Magnetizing

No Current A-N B-N C-N a-n b-n c-n A B C

A-B B-C C-A a-b b-c c-a

1.

2.

3.

4.

5.

VECTOR GROUT TEST:

A 415V 3 phase supply connected to H.V. terminals with normal earth

connection at star point removed and A-a connected together:

Bet- Volts Bet- Volts Bet- Volts Bet- Volts Bet- Voltsween ween ween ween ween

A-B A-a B-a C-a a-bB-C A-b B-b C-b b-cC-A A-c B-c C-c c-a

Sketch the connections Vector symbol from Tests


BHELSIGNATURE

DATE:


22/53


PLANT ITEM : 33/6.6 KV & 15.75/6.6 KV TRANSFORMER REF: NO.: E.1.2ITEM

2.0 TEST PROCEDURE

BUCHHOLZ DRVICE:

Manufacturer __________________ Type ______________ Inclination : Longitudinal _____________________

Lateral _____________________

Quantity of air to operate :

Alarm contacts : ________________

Trip contacts : ________________

Approx. minimum air pressure to operate surge contacts and type of equipment used

Check IR between and to earth of trip and alarm circuits.

Winding temperature indicator (thermal Image type) obtainmanufacturers calibration results and copy of C.T. tests carried out

before erection.

Inject equivalent of full load current into heater circuit and record valuewhen condition are stable.

No. 1 WTI No. 2 WTI StandardThermometer

Initial oilTemperature

Temp. equivalentOf F.L. after ________ mts.


BHELSIGNATURE

DATE:


23/53

ELECTRICALSTATION : STANDARD CHECKLIST SHEET 11OF 12


2.0

2.8

2.9

TEST PROCEDURE

Record contact settings :

Alarm : _____________ deg C

Trip : ____________ deg C

C.T. Ratio __________________

Heater coil Resistance = ______________________

Compare calibration with manufacturers test results.

Check IR between and to earth of alarm & trip circuit of temperatureindicator.

Check calibration of oil temperature indicator using heated bath andstandard thermometer.

StandardThermometer deg C

O.T.I. deg C

Check IR between and to earth of alarm and trip circuit.

When auxiliary supplies are available, carry out functional checks toprove the correct operation of the cooling system controls as per relevantdrawings, including remote controls, alarms and indications. Also checkthe correct rotation of air circulating fans.


BHELSIGNATURE

DATE:


24/53



2.0

2.10

2.11

2.12

2.13

TEST PROCEDURE

When auxiliary supplies are available, carry out functional checks toprove the correct operation of the tap changer (where applicable) in itsfull range as per the relevant drawing, including remote controls, alarmsand indications.

Prove the operation of transformer temperature alarm and trip to remotepanels.

Prove the operation of buchholz alarm and trip to remote panels.

Prove neutral C.T. cabling to relay panel.


BHELSIGNATURE

DATE:


25/53


PLANT ITEM : 6.6 KV / 415 V TRANSFORMER REF: NO.: E.1.3

SUPPLIER _____________________________________________________________

MANUFACTURER _______________ TYPE ____________ SRL.NO. _____________

A.C CURRENT RATING __________________________________________________

A.C. VOLTAGE RATING _________________________________________________

LOCATION ______________________________________________________

CIRCUIT ________________________________________________________

IDENTIFICATION _________________________________________________


BHELSIGNATURE

DATE:


26/53


PLANT ITEM : 6.6 KV / 415 V TRANSFORMER REF: NO.: E.1.3NO

1.

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

A C T I V I T Y

GENERAL INSPECTION AND CHECKS

Check that the transformer and oil its accessories are erected completelyand the pre-erection inspection & testing certificates are available.

Check that the transformer has adequate ventilation and free access fromall sides.

If the transformer is situated indoors, see that transformer room is wellventilated.

Check that transformer, bushings, insulators, cables, tap changer are freefrom any damage.

Check that all foundation bolts and other fixing arrangements/ of equipments are properly tightened.

Check that stops are provided where the transformer is mounted onrollers.

Check that the marking of terminals are correct.

Check that the tightness of all cable and wiring connection.

Check the colour code of the cables for correctness.

Check that all cable and wiring connections are done as per wiringdrawings.

Check that name plate are clear and are properly fixed.


BHELSIGNATURE

DATE:


27/53



1.12

1.13

1.14

1.15

1.16

1.17

1.18

1.19

1.20

1.21

1.22

A C T I V I T Y

Labeling & identifications of different parts are correct and satisfactory.

Fire fighting system is adequate and satisfactory.

Surrounding areas are clean and safe for commissioning operation andmaintenance.

Check the cleanliness of all contact surfaces, insulator surfaces.

Check the explosion vent and its diaphragms if any.

Check the breather system and its desiccants conditions.

Check that bushing arcing horns (if provided ) are fixed properly and their gap adjusted as per drawing.

Check all protective covers and shields are fixed properly.

Release any air trapped in the buchholz relay, Mercury switches of buchholz relays if clamped for transportation should be put into servicecondition check for correct mounting.

Check all indicating and controlling instruments are properly placed intheir respective positions.

Check the transformer oil tank levels.


BHELSIGNATURE

DATE:


28/53


29/53



2.0

2.1

2.2

A C T I V I T Y

TESTS AND TESTING PROCEDURES:

IR TESTS:

With a 1000 V or 2.5 Megger measure the following insulationresistances.

IR Value with : _________________ V . Megger. Ambient temp. : _________________ deg C

BETWEEN HV TO E :

i. ___________________ Mega-ohms.ii. ___________________ Mega-ohms.iii. ___________________ Mega-ohms.

BETWEEN LV TO E :


BETWEEN HV TO LV :


After the above tests put back all connection properly.

Check for proper insulation resistance of all control and Protective wiringsafter removal of earth link and fuses which are to be put back after tests.


BHELSIGNATURE

DATE:


30/53



2.3

2.4

2.5

2.6

A C T I V I T Y

Check the continuity of windings

HV ___________________ LV ____________________

VOLTAGE RATIO RESTS:

With a LT 3 phase supply applied on the HV side, measure thecorresponding LV side voltages on all taps and on all phases byoperating the tap switch. (the values should be similar for all the phases)

Magnitising current test with LT voltage applied to the HV side, measurethe magnetising current on all taps and on all phases. These valuesshould be in the order of a few milli-amps.

Vector group tests.

Carry out vector group tests of the transformer by applying 3 phase, 415V to the HV terminals with normal earth connections to the star pointremoved.

Connect one HV terminal to one LV terminal.

With transformer on nominal taps measure the following voltages.


BHELSIGNATURE

DATE:


31/53



2.6

2.7

2.8

2.9

2.10

A C T I V I T Y

TABLE

HV TO LV =

Bet- Volts Bet- Volts Bet- Volts Bet- Volts Bet- Voltsween ween ween ween ween

A-B A-a A-b A-c a-b

B-C B-a B-b B-c b-cC-A C-a C-b C-c c-a

Where A, B, & C = HV Terminals.a, b, & c = LV Terminals.

Draw the vector diagrams from the results so obtained during the testsand compare the same with that given or the manufacturer.

All connections are to be normalized after the tests.

Samples of oil will be taken and sent to the chemical laboratory to betested.

Winding temperature CT is to be tested for ratio, magnetizing and polaritychecks.

All the alarm contacts when closed should initiate the visual and audioindications.

The trip contacts when closed should trip the trip relay and given thevisual indication and alarm,


BHELSIGNATURE

DATE:


32/53



2.11

2.12

A C T I V I T Y

BUCHHOLZ DEVICE TESTS :

i. Inclination (degrees)

Longitudinal (3 deg 7 deg ) _____________________ Lateral (0 deg 5 deg ) _____________________

ii. Quantity of air to operate the alarm contacts.

C.C.S. make __________________ C.C.S. Breaks __________________

iii. Surge contacts : Approximate minimum air pressure required to operate the surgecontacts __________________ .

iv. Make the gas contacts to operate alarm relay.

v. Make the trip contacts to operate flag relay and trip relaysimultaneously.

vi. Release all air from Buchholz Relay.

W T I TESTS :

- Heater coil circuits :

Coil resistance = ______________________ Ohms.Shunt resistance

Across heater = _____________________ Ohms.


BHELSIGNATURE

DATE:


33/53



2.12

A C T I V I T Y

- Heater coil tests:

Current injected (F.L.C.) _______________ amps.Initial temperature _______________ deg C.Top oil temperature _______________ deg C.Temperature increment ________________ deg C. / mins.Steady state temperature _________________ deg C.

- Calibration test on WTI indicator :

Test Temperature WTI

25 deg C30 deg C40 deg C50 deg C60 deg C70 deg C80 deg C90 deg C

100 deg C

- Check alarm contact by operating alarm relay.

- Check trip contacts by operating flag relay and trip relay.

A. - Alarm contact settings ________________ .B. - Trip contact settings ________________ .


BHELSIGNATURE

DATE:


34/53



2.13

A C T I V I T Y

OFF LOAD TAP CHANGER TESTS :

Tap changer counter reading :

Initial _________________ Final _________________

Raise and lower the handle locally in full range manually and see thecircuit continuity at each tap position and check also the handle interlock.


BHELSIGNATURE

DATE:


35/53

S E C T I O N - B


36/53


PLANT ITEM : D.C. BATTERY (ANY VOLTAGE) REF: NO.: E.4.1

UNIT ____________________________________________________________

MANUFACTURER ____________________ SYSTEM/CIRCUIT____________

TYPE _____________________________ SERIAL NO.___________________

OUTPUT RATING (BOOST) __________________ VOLTAGE ______________

OUTPUT RATING (FLOAT) ________________ RATED CAPACITY _________

CHARGE RATE (BOOST) ____________ CHARGE RATE (FINISH) _________

LOCATION ______________________________________________________


BHELSIGNATURE

DATE:


37/53


PLANT ITEM : D.C. BATTERY (ANY VOLTAGE) REF: NO.: E.4.1NO

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

1.15

INSPECTIION AND CHECKS

Access to battery room satisfactory.

Permanent and adequate lighting available.

Labeling and identification of battery and battery room satisfactory.

Equipment undamaged and mounted satisfactorily.

Paint work and finishing of equipments and rooms satisfactory.

Satisfactory fire protection available.

Battery room permanent door fitted and lockable.

Telephone installed nearby and operational

NO SMOKING and EXIT Notices displayed.

Battery room clean and free from debris.

Battery room ventilation system satisfactory.

Running water and eyewash bottle available.

Hydrometer, thermometer and battery voltmeter available.

Battery room floor and walls acid resistance.

Measure insulation resistance of bus bars to earth by 500 V megger.

Positive to earth __________ Negative to earth _______________ .


BHELSIGNATURE

DATE:


38/53



1.0

1.16

1.17

1.18

1.19

1.20

1.21

1.22

1.23

1.24

1.25

INSPECTION AND CHECKS

Correct number of cells erected.

All cells in sound physical condition.

All cell filler caps secure and vent holes free.

All cells correctly fitted for polarity

All intercell connections are tight and greased.

All cells filled to correct level.

All cell specific gravity measured and results recorded.

Bus Bars identified for polarity.

Pilot cells selected and identified.

Cable from charger to battery laid and polarity identified.


BHELSIGNATURE

DATE:

ELECTRICAL


39/53

STATION : STANDARD CHECKLIST SHEET 4 OF 8PLANT ITEM : D.C. BATTERY (ANY VOLTAGE) REF: NO.: E.4.1NO

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

ENERGISING CHECKS AND DISCHARGE TEST

Ensure that section-2.0 of this document has been completed.

Safety clearance notification for the system issued and effective.

Ensure D.C. distribution board is isolated from the circuit.

Confirm battery charger is available to boost charge the battery.

Restore battery link and switch on outgoing D.C. switch of boost charger to connect into battery.

Set the voltage control device of boost charger to minimum position andswitch ON A.C. supply to the charger.

Slowly increase the current to the constant value as specified by themanufacturer.

Charge for 60 hrs. at specified rate.

During charging record specific gravity, voltage and temperature of eachcell at interval of time.

After completion of 60 hrs. charging keep battery on open circuit for 4 hrs.

Again charge for 40 hrs. at specified rate to give input of specified AH.


BHELSIGNATURE

DATE:


40/53


PLANT ITEM : D.C. BATTERY (ANY VOLTAGE) REF: NO.: E.4.1.NO

2.0

2.12

2.13

2.14

2.14

2.15

2.16

2.17

2.18


Maintain the level of electrolyte by adding acid as used for initial filling.

When cells start gassing freely battery is supposed to be charged and willattain specified specific gravity and voltage.

NOTE: Do not terminate the charging even if specific gravity and voltagereaches required value until the specified Amp. Hrs. input is fed in to thebattery.

Observe the temperature rise of electrolyte. At no stage during chargingthe temperature be allowed to exceed 50 deg C. If temperature tends toexceed 45 deg C, reduce the current to 1/3 value and increase the timeof charging.

Inspect during charging all connections and joints for excessivetemperature rise.

With battery fully charged keep it on open circuit for 12 hrs.

Record sp. Gravity and voltage and adjust it required value before

discharge starts.

Discharge the battery through a variable resistance at specified rate.


BHELSIGNATURE

DATE:


41/53



2.0

2.19

2.20

2.21

2.22

2.23

2.24

2.25


During discharge record hourly the temperature, current, voltage andspecific gravity of pilot cells.

Stop the discharge when the voltage for cell falls to minimum permissiblevalue specified by the manufacturer.

Investigate any suspect cell which has failed to pick up during firstcharging and discharging cycle.

Calculate the AH capacity of the battery by multiplying the current and theperiod of discharge in hrs. and check whether it conforms to capacity of battery as quoted.

Recharge the battery at specified boost charge rate till gassing starts.Thereafter reduce the charging to finishing rate and charge till maximumsp. Gravity and voltage are attained and remain constant for consecutivehalf hourly reading.

Again discharge the battery as specified in 2.17 and calculate. AH

capacity.

Perform the cycle of charging and discharging as above twice. If in anyone of these the AH capacity of battery calculated exceeds the ratedcapacity, the battery is said to have passed the capacity test.


BHELSIGNATURE

DATE:


42/53



2.0

2.26

ENERGISING CHECKS AND DISCHARCH TEST

When the charge/ discharge cycle is completed charge the battery fullstate of charging with one of the float charger trickle charging it.


BHELSIGNATURE

DATE:


43/53


PLANT ITEM : D.C. BATTERY (ANY VOLTAGE) REF: NO.: E.4.1

Hrs. Cell No.

SpecificGravity

Voltage Temp. Cell No.

Specificgravity

Voltage Temp. Date


BHELSIGNATURE

DATE:


44/53


PLANT ITEM : D.C. BATTERY CHAGER REF: NO.: E.4.2

UNIT ____________________________________________________________

MANUFACTURER ____________________ SYSTEM ___________________

TYPE _____________________________ SERIAL NO.___________________

OUTPUT RATING (BOOST) ____________ MAIN VOLTAGE ______________

OUTPUT RATING FLOAT-1 : _______________ RATED CAPACITY _________

FLOAT- 2 :_________ CHARGE RATE (FINISH) _________

LOCATION ______________________________________________________


BHELSIGNATURE

DATE:


45/53

ELECTRICALSTATION : STANDARD

CHECKLISTSHEET 2 OF 6

PLANT ITEM : D.C. BATTERY CHAGER REF: NO.: E.4.2NO

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

INSPECTIONS AND CHECKS

Access to battery charger satisfactory.


Charger cubicle labeling and identification permanent and satisfactory.

Equipments undamaged and mounted satisfactorily.

Telephone available nearby.

Charger surroundings clean and free from any debris.

Charge ventilation satisfactory.

Charger cubicles connected to earth system.

All cover fitted.

Paint work and finishing complete and satisfactory.

Battery chargers checked for all connections and wirings with referenceto relevant drawings.

All alarms / indications are working.

All contactor checked for free movement.


BHELSIGNATURE

DATE:


46/53


PLANT ITEM : D.C. BATTERY CHARGER REF: NO.: E.4.2NO

1.0

1.14

1.15

1.16

1.17

1.18

INSPECTIONS AND CHECKS

Check on control cards:

i. Components secure and soldered.:

ii. Printed circuit board undamaged :

iii. Wiring of test points to front face :board of module undamaged and

satisfactory.

iv. Test points on face board correctly :

v. Fixing of module into its position :Satisfactory.

vi. All external control wiring checked :

vii. Labeling of modules is fixed andpermanent so that each module

position is clearly identified.

Check fixing of cover on the complete modules assembly is satisfactory.

Ensure static checklist on SCRs and diodes in the power circuit is carried out.

Check provision of lamp and heater in the cubicle.

Check earthing of cubicle and doors.


BHELSIGNATURE

DATE:

Phase Card A B C


47/53


PLANT ITEM : D.C. BATTERY CHARGER REF: NO.: E.4.2NO

2.1

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

ENERGISING CHECKS AND LOAD TEST

Sketch and identify the integrated plant affected by this energizing.

Ensure section-2 (Inspections and checks) has been completed.

Confirm A.C. supply to all the chargers is isolated.

Confirm battery link isolated.

Confirm battery charger circuit isolated from D.C. switch board.

Check all fuse are of correct size.

Measure I.R. of battery chargers and bus bars.

M ohms

Measure I.R. of output cable to battery and switch board.

M ohms


BHELSIGNATURE

DATE:


48/53



2.0

2.9

2.10

2.11

2.12

2.13

2.14

2.15

2.16

2.17

ENERGISING CHECKS AND LOAD TEST

Check potentiometers provided on front panels of all the chargers atminimum position.

Switch ON A.C. supply isolator of float charger-1and select charger tomanual mode.

Check phase sequence of input power and reset U\V and supply failrelay.

Measure A.C. input voltage.

R to YY to BB to B

Switch ON float charger-1 contactor and measure output D.C. voltageand its polarity.

The output voltage may be varied by potentiometer but may not be

stabilized in manual mode.

Select float charger-1 to AUTO the output voltage with settle down to afactory set value and will stabiles to + 1% of the set value.

Close A.C. supply isolator of float charger-2.

Give closing impulse to its contactor and check he contactor of floatcharger-2 does not close.

Switch off float charger-1.


BHELSIGNATURE

DATE:


49/53


50/53


PLANT ITEM : D.C BATTERY CHARGER REF: NO.: E.4.3

SUPPLIER______________________________________________________

MANUFACTURER______________________________TYPE ______SRL.NO._____

POWER SUPPLIES______________________VOLTS_____________AMPS____HZ

LOCATION___________________________________________________________

CIRCUIT_____________________________________________________________

IDENTIFICTION_________________________________________________________


BHELSIGNATURE

DATE:


51/53


PLANT ITEM : D.C BATTERY CHARGER REF: NO.: E.4.2

NO

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

INSPECTION AND CHECKS

Access to switch board satisfactory.


Switch board undamaged and mounted satisfactorily.

Painting and finishing of switch board complete and satisfactory.

Fire protection available.

Telephone installed nearby.

Switchboard earth connection to main earth system complete andadequate.

Bus bar connections tight and complete.

Bus wiring connections tight and complete.

All covers fitted and bolted up.

Padlocks supplied, fitted and keys secured.


BHELSIGNATURE

DATE:


52/53


53/53

Documents

ELE Std. Check List VOL-1