Title Battery Maintenance Strategy Sheet # 1 of 7 Owner GDH -

Electrical
Engineering
Strategy # PML201.09 Issue date 31-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0

1. STRATEGY COVERAGE

System/Equipment Systems/ Equipment Other Relevant

# Function
Included Not Included Strategies
No-break power Battery types: Portable lighting PML201.10 -
supplies to vital o Nickel cadmium, AC uninterruptible Uninterrupted
services in the case of vented power supply Power Supply (UPS)
main generation o Nickel cadmium, DC uninterruptible PML201.13 - Lighting
1 failure. valve regulated and power supply
low maintenance
o Lead acid vented
o Lead acid, valve
regulated (Sealed
VRLA)

* = (PS) Performance Standard

SAP BP GAME Object SAP GAME SAP BP Class

SAP BP Description EIS Description
Object Type Type Description (EIS_)
Dry NiCad
E_BAT_DNIC
Battery
Vented lead
E_BAT_VLA
battery
Valve
E_BAT_VRLA regulated lead
ELBA Batteries battery EIS_EL_BATTER Battery
Valve NiCad
E_BAT_VRNI
battery
Wet NiCad
E_BAT_WNIC
Battery
E_BAT_X Other battery

2. DOMINANT FAILURE MODES

Hidden Age
Failure Modes
Failure Related
Battery Failure Y Y
Electrolyte degradation Y Y
Boost charger failure Y Y
Terminal corrosion N Y
Electrolyte level (quantity) Y Y
Failure of battery cell capacity N N
Reduced battery terminal voltage due to failed cell Y N
Specific Gravity Changes Y N
Excessive Temperature Y N
Defective Post Seals N N
Jar Case Cracks from swelling N Y
Component failure Y Y
Loose Connections/ terminals overheating N Y
Contamination Y Y
Ventilation Failure Y Y
Ground Fault in DC system including battery Y Y
Title Battery Maintenance Strategy Sheet # 2 of 7 Owner GDH -
Electrical
Engineering
Strategy # PML201.09 Issue date 31-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0

3. MAINTENANCE ACTIVITIES

Failure Optimiza-
Type modes Intent Extent Standard Text Freq tion Comments
covered Method
N/A
Operational
Checks

N/A N/A N/A N/A N/A N/A

Terminal
corrosion
Contaminati
on
Ventilation
Batteries to be
Failure
Regular Lead checked on a
Electrolyte XX_TL_PML201.09_01 3M RCM
inspection Acid system or
degradation
routine basis.
Battery
Failure
Specific
Gravity
Condition Based Maintenance

Changes
Connections/
terminals
overheating
Mechanical
failure.
Component
Detection of
failure.
abnormal
Battery
condition.
Failure Batteries to be
Battery system
Terminal checked on a
inspection/ Ni-Cd XX_TL_PML201.09_02 6M RCM
corrosion system or
checks.
Electrolyte routine basis.
Thermography.
degradation
Cell order
Specific checks.
Gravity
Changes
Contaminati
on
Ventilation
Failure
Maintenance
Preventive

N/A N/A N/A N/A N/A N/A N/A

Maintenance
Corrective

Complete
Battery All Spare cells
Battery
condition. Batteries required.
Failure
Title Battery Maintenance Strategy Sheet # 3 of 7 Owner GDH -
Electrical
Engineering
Strategy # PML201.09 Issue date 31-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0

4. SAP IMPLEMENTATION

Task lists:
- Lead Acid Battery PM Tasks
- NiCad Battery PM Tasks

General Task List

Lead Acid Battery PM Task List Group Maintenance
Header XXELBA01 XX02
Tasks Name Strategy:
Description
Reference Object
ELBA Application Level Item
Type
Discipline/ Complia
Count MA Packag Dura
Operation Standard Text Work nce MIC No.
er /ID T e Freq tion
centre Category
3M-Lead
Acid
XX_TL_PML201.0
0010 Battery PIN DUMELEC 3M I
9_01
Minor
Inspection

General Task List

Task List Group Maintenance
Header NiCad Battery PM Tasks XXELBA02 XX02
Name Strategy:
Description
Reference Object
ELBA Application Level Item
Type
Discipline/ Complia
Count MA Packag Dura
Operation Standard Text Work nce MIC No.
er /ID T e Freq tion
centre Category
6M-NiCad
Battery XX_TL_PML201.0
0010 PIN DUMELEC 6M I
Minor 9_02
Inspection
 Title Battery Maintenance Strategy Sheet # 4 of 7 Owner GDH -
Electrical
Engineering
Strategy # PML201.09 Issue date 31-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0

5. STANDARD TEXTS
Failure Optimiza-
modes Intent Extent Standard Text Freq tion Comments
covered Method
Terminal
corrosion
Contaminati
on
Ventilation
Batteries to be
Failure
checked on a
Electrolyte Fault Finding Lead Acid XX_TL_PML201.09_01 3M RCM
system or routine
degradation
basis.
Battery
Failure
Specific
Gravity
Changes

A.) Objective:
The purpose of this maintenance routine is to check the Lead Acid batteries for anything untoward, which
may result in an unplanned loss of service.

B.) Required Steps:

1. Visually inspect battery banks for signs of corrosion, contamination and damage
2. Check that all covers are in place, secure and are clean. Check cell containers for any signs of
distortion.
3. Check cables, glands and earthing are secure.
4. Ventilation: Check that the battery room ventilation system is operational. Also check the loss of
ventilation alarm and interlock with boost charging if fitted
o o
5. The battery room shall be clean of debris and the temperature within a range of 20 to 25 C.
6. Float Voltage and Current Values: Measure and record system float voltage and current. The
measurement should be taken at the battery termination point. The results should be recorded and
compared to the reading on the charger panel meter.
7. Pilot Cell Readings: Identify 5 pilot cells to take the following readings. Record the pilot cell readings
in the work order notes. If possible these cells should be on different racks.
Record each individual pilot cell charging voltage.
Following actions apply only to non valve regulated Pb cell types
Record each individual pilot cell electrolyte temperatures. Verify the temperatures are in normal
o o o
range, usually 20 to 25 C and with a variance no greater than 1 C between individual cells.
Record specific gravity of the Pilot cells.
Note: The specific gravity should be corrected for temperature. It is important to take specific
gravity readings prior to adding water or acid to the cells.
8. Electrolyte Level: Check visually the electrolyte level. The topping-up is recommended when the
electrolyte level reaches the minimum level mark but must be carried out before it reaches the
warning level. Use only distilled water to top up. Experience will tell the time interval between
topping up.
9. Cell Cleanliness: If there is dirt or debris on the cells or connectors wipe them with a clean, lint free
moistened cloth. Do not allow any debris to fall into any of the cells.
10. Lighting: Verify all lighting is operational.
11. Clean the battery if required. Do not use a wire brush or solvent of any kind.
12. If battery terminals are loose then to be torque as per OEM).
13. Grease the battery terminals if required with neutral grease or petroleum jelly.

C.) Minimum Assurance Tasks:

 Title Battery Maintenance Strategy Sheet # 5 of 7 Owner GDH -
Electrical
Engineering
Strategy # PML201.09 Issue date 31-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0

N/A
Optimiza-
Failure modes
Intent Extent Standard Text Freq tion Comments
covered
Method
Connections/
terminals
overheating
Mechanical
failure.
Detection of
Component
abnormal
failure.
condition. Battery Batteries to be
Battery Failure
system checked on a
Terminal NiCad XX_TL_PML201.09_02 6M RCM
inspection/ system or routine
corrosion
checks. basis.
Electrolyte
Thermography.
degradation
Cell order checks.
Specific Gravity
Changes
Contamination
Ventilation
Failure

A.) Objective:
To check the Ni-Cad batteries for anything untoward to avoid an unplanned loss of service.

B.) Required Steps:

1. Visually inspect battery banks for signs of corrosion, contamination and damage.
2. Check that all covers are in place, secure and are clean. Check cells for any signs of bulging.
3. Check cables, glands and earthing are secure.
4. Ventilation: Check that the battery room ventilation system is operational. Also check the loss of
ventilation alarm and interlock with boost charging if fitted.
5. The battery room shall be clean of debris and the temperature is consistent with original design
temperatures.
6. Float Voltage and Current Values: Measure and record system float voltage and current. The
measurement should be taken at the battery termination point. The results should be recorded and
compared to the reading on the charger panel meter.
7. For non valve regulated cell types
Electrolyte Level: Check visually the electrolyte level. The topping-up is recommended when the
electrolyte level reaches the minimum level mark but must be carried out before it reaches the
warning level. Use only distilled water to top up. Experience will tell the time interval between
topping up.
8. Cell Cleanliness: If there is dirt or debris on the cells or connectors wipe them with a clean, lint free
moistened cloth. Do not allow any debris to fall into any of the cells.
9. Check the flame-arresting vents are tightly fitted and without any deposits.
10. Lighting: Verify all lighting is operational.
11. Clean the battery if required. Do not use a wire brush or solvent of any kind.
12. If battery terminals are loose then to be torque as per OEM
13. Grease the battery terminals if required with neutral grease or petroleum jelly.

C.) Minimum Assurance Tasks:

N/A
Title Battery Maintenance Strategy Sheet # 6 of 7 Owner GDH -
Electrical
Engineering
Strategy # PML201.09 Issue date 31-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0

6. IMPLEMENTATION CONSIDERATIONS

Category* Consideration

Execution Frequency may require adjustment according to the batterys duty, system criticality or both.
Condition monitoring by visual inspection, thermography, Cell voltage readings and battery
Resources
discharge testing are the normal routine maintenance activities. These are to be scheduled.
Resources A specialist vendor may be required for battery discharge testing.
Some systems may have permanent battery monitoring systems installed and therefore separate
Cell order checks may then not be required.
Inspection frequencies can be increased depending on experience at site.
Execution For Pb valve regulated batteries, the intervals between inspections should reduce as battery
approaches anticipated end of life.
Performance standards ER005 UPS discharge function test and IC002 3.2 Battery charger
shutdown function tests are included as part of Ups maintenance strategy.
Pb valve regulated batteries shall be replaced before end of life point is reached as they exhibit a
sudden total failure mode.
Spare Parts
NiCad battery cells may need to be replaced at intervals of around 25 years. Reference should be
made to the manufacturers recommendations and results of condition monitoring.
Batteries regarded in this strategy are hazardous and will require special treatment before
disposal, use specialist recyclers, or waste disposal companies. Associated regulations for each type
are given below:

Ni-Cad Batteries:
RCRA-regulated hazardous waste due to the characteristic of toxicity (cadmium, EPA
Environment Hazardous Waste Number D006)
EU Waste Code 16 06 02

Lead-Acid Batteries:
RCRA-regulated hazardous waste due to their lead content EPA Hazardous waste Number
D008)
EU Waste Code 10 06 01
PB valve regulated cells require an ambient temperature of between 20 and 25 deg C to achieve
projected lifetime. Operation at temperatures outside this range will result in performance and / or
Environment
lifetime reduction

*Criticality, Medium, Spare Parts, Environment, Legislation, Execution, Policy, Interferences, Resources, Other

7. REFERENCES

Source Document Title & Number

Shell Design Engineering
Practice (DEP)
International Standards
RMP 63.10.08.50-Gen. - Maintenance of electrical installations and equipment
DEP 80.64.10.10 Electrical Safety Rules
C.E.I. IEC 79-17 Electrical Apparatus for Explosive Gas Atmospheres Part 17.
IEC 60050 - International electro technical vocabulary. Chapter 486: Secondary cells and
batteries.
IEC 60086-2, BS Batteries - General
Title Battery Maintenance Strategy Sheet # 7 of 7 Owner GDH -
Electrical
Engineering
Strategy # PML201.09 Issue date 31-01-2012 Security Restricted
Discipline Electrical Review date 24-01-2014 Revision 5.0

8. CHANGE LOG

Date Changes by Changes/ Comments Revision

Copied content from old template into new

template
Changed name of document according to
20-05-2011 Justin van Loon 0.1
naming convention
Added change log as separate chapter at
the end
Formatted document according to new
24-05-2011 Justin van Loon 0.2
updated template
14-06-2011 Mark Ewe Final Draft ready for Discipline Review 0.3
Split up of strategy into 201.09 Battery &
21-06-2011 Shell Charger and 201.10 UPS maintenance 0.4
strategies
11-08-2011 Add Latent Consolidation rework 0.5
11-01-2012 Parameswaran Raman Rework 0.5a
18-01-2012 S.K.Dwivedi Review 1
24-01-2012 Peter Freeman Review 1.1
30-01-2012 Pim Dekker Ready for PTE Approval 2.0
31-01-2012 Wim de Wilt Strategy Approved by PTE 3.0
01-11-2012 Tiemon Dokter Template changes 3.1
30-10-2012 Wim de Wilt Strategy Approved by GDH 4.0
27-09-2013 Justin Brunsting Template changes 4.1
24-01-2014 Wim de Wilt Strategy Approved by PTE 5.0