EBC1

NOTES FOR GUIDANCE ON

THE SUPPLY, CHARGING, INSTALLATION, SETTING

TO WORK, MAINTENANCE AND SAFETY OF
BATTERIES

MAY 1984
J025 (Rev 11/02)
.
 EBC1

CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iv

1. SCOPE 1

2. FIELD OF APPLICATION 1

3. REFERENCES 1

4. DEFINITIONS 2

5. BATTERIES 3

5.1 Types of batteries 3

5.2 Characteristics and comparisons of batteries 4

6. APPLICATIONS 8

6.1 Applications of batteries and battery containers 8

6.2 Application of battery and battery charger systems 8

7. BATTERY CHARGING AND CONTROL EQUIPMENT (EXCLUDING BATTERIES) 9

7.1 Mode of operation of circuits using constant voltage battery chargers 9

7.2 Cubicle construction 10

7.3 Cubicle equipment 10

7.4 Internal wiring 11

7.5 Cable entry gland plates 12

7.6 Terminals 12

7.7 Earthing 12

7.8 Labelling 12

7.9. Tools 13

7.10 Documentation 13

8. COMBINED BATTERY AND BATTERY CHARGING EQUIPMENT 13

9. QUALITY SYSTEMS 13

10. INSTALLATION OF BATTERY SYSTEMS 14

10.1 General 14

10.2 Battery rooms 14

10.3 Installation of batteries 17

10.4 Preparation of batteries for service 18

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Page

11. PRE-SERVICE INSPECTION, CHARGING AND TESTS 19

11.1 General inspection 19

11.2 Inspection and test of charging and control equipment 19

11.3 Inspection and charging of batteries 19

11.4 Final battery installation check with load connected 20

12. BATTERY MAINTENANCE 20

12.1 General requirements 20

12.2 Lead-acid battery maintenance 21

12.3 Nickel-cadmium battery maintenance 22

12.4 Disposal of battery electrolyte 23

12.5 Sealed batteries 23

TABLES

1 Typical lead-acid battery characteristics 4

2 Typical recharge times for Plante cells 5

3 Typical nickel-cadmium battery characteristics 7

4 Application of batteries 8

5 Applications of battery containers (cell enclosure) 8

6 Typical values of charging current 15

7 Typical SG values for lead-acid cells at 15 0 C 21

FIGURES

1 Typical A h capacity / discharge time characteristics of lead-acid Plante cells 25

2 Typical charge characteristics (at 15 0 C ) of lead-acid Plante cells 26

3 Typical charge characteristics of lead-acid Plante cells at constant voltage 27

4 Discharge characteristics (A h capacity / discharge time) for nickel-cadmium cells 28

5 Charge characteristics for nickel-cadmium cells 29

APPENDICES

A TECHNICAL SCHEDULE FOR BATTERIES AND BATTERY

CHARGER SYSTEMS TO TRANSCO SPECIFICATION EBC1 31

B SPECIMEN VENTILATION CALCULATIONS 36

C RELATED DOCUMENTS 40

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FOREWORD

Comments and queries regarding the Technical content of this engineering document should be directed to:

Engineering Policy
Transco
Brick Kiln Street
Off Coventry Road
Hinckley
Leicestershire
LE10 0NA

Further copies of this engineering document can be obtained from Dataform Print Management using the
print requisition form G004 quoting the Form Number of this Transco engineering document (not the
designation) and your cost code.

Transco documents are revised, when necessary, by the issue of new editions. Users should ensure that they
are in possession of the latest edition by referring to the Transco Register of Engineering Documents
available on TransNet.

Compliance with this engineering document does not confer immunity from prosecution for breach of
statutory or other legal obligations.

Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.

DISCLAIMER

This engineering document is provided for use by Transco and such of its contractors as are obliged by the
terms and conditions of their contracts to comply with this engineering document. Where this engineering
document is used by any other party it is the responsibility of that party to ensure that the engineering
document is correctly applied.

J025 (Rev 11/02) - iii -

EBC1

BRIEF HISTORY

First published as BGC/PS/EBC1 May 1984

Amendment No. 1 published November 1985
Amendment No. 2 published June 1992

Editorial update to reflect demerger November 2000 June 2001

Editorial update to reflect merger October 2002 November 2002

© Transco plc.

This engineering document is copyright and must not be reproduced in whole or in part by any means
without the approval in writing of Transco plc.

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NOTES FOR GUIDANCE ON

THE SUPPLY, CHARGING, INSTALLATION, SETTING
TO WORK, MAINTENANCE AND SAFETY OF
BATTERIES

1. SCOPE
1.1 These Transco Notes for Guidance * give guidance on the supply, charging, installation, setting
to work, maintenance and safety of battery chargers and of both lead-acid type and nickel-cadmium type
batteries for use in non-hazardous areas on all Transco sites.
* Hereinafter referred to as 'this specification'.

1.2 This specification relates to batteries having nominal terminal voltages up to 500 V and battery
chargers operating from low voltage a.c. supplies (normally exceeding 50 V a.c. but not exceeding
1000 V a.c. between conductors or 600 V a.c. between conductors and earth).

1.3 Appendix A details a schedule of equipment, data, etc., relating to the subject of this document.

2. FIELD OF APPLICATION
This specification is applicable to situations where batteries are required for the following duties:

a) Switchgear operation
b) Standby power supplies
c) Communication and instrumentation systems
d) Emergency lighting
e) Alarm systems

It does not cover batteries for use in mobile and portable equipment or batteries for automotive use.

3. REFERENCES
This specification makes reference to the documents listed below. Unless otherwise specified the latest
editions of these documents, including all addenda and revisions, shall apply.

British Standards

BS 88 - Cartridge fuses for voltages up to and including 1000 V a.c. and

1500 V d.c.

BS 493 - Specification for air bricks and gratings for wall ventilation

BS 2092 - Specification for industrial eye-protectors

BS 3031 - Sulphuric acid for use in lead-acid batteries

BS 4174 - Self-tapping screws and metallic drive screws

BS 4974 - Water for lead-acid batteries

BS 5420 - Specification for degrees of protection of enclosures of switchgear

and controlgear for voltages up to and including 1000 V a.c. and
1200 V d.c.

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EBC1

BS 5750 - Quality systems

BS 6290 - Lead-acid stationary cells and batteries:

Part 1 - Specification for general requirements
Part 2 - Specification for lead-acid high performance Planté positive
type

BS 6431 - Ceramic floor and wall tiles:

Part 6 - Specification for dust - pressed ceramic tiles with a low
water absorption (E ≤ 3%). Group B1. ( ≡ EN 176)

British Telecom specification

RC5000 - General requirements for line and radio transmission equipment

detailed in specifications issued by the Development Department

Institution of Electrical Engineers publication

- Regulations for electrical installations

Transco specifications

PA7 - Specification for stoved paint finishing

SFP2 - Code of practice for fire precautions and fire and gas detection for
buildings, enclosures and indoor installations.

4. DEFINITIONS
For the purposes of this specification the following definitions shall apply.

Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.

secondary cell: a voltaic cell which, after discharge, can be brought back to its initial charged condition by
passing a current through it in the reverse direction to that of discharge.

stationary cell: a voltaic cell which is erected on a fixed site and is not intended to be moved from place to
place during its life.

ampere-hour efficiency: ( a d x t d ) / ( a c x t c ).*

watt-hour efficiency: ( v d x a d x t d ) / ( v c x a c x t c ).*

* Where: v d = average voltage during discharge a c = average amperes during charge

v c = average voltage during charge t d = time of discharge
a d = average amperes during discharge t c = time of charge

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lead-acid cell: a cell in which the electrolyte is dilute sulphuric acid and which is fitted with plates in which
the active materials are:

a) Lead dioxide - positive electrode.

b) Spongy lead - negative electrode.

nickel-cadmium cell: a cell in which the electrolyte is a solution of potassium hydroxide and which is
fitted with plates in which the active materials are:

a) Nickel hydrate and graphite - positive electrode.

b) cadmium hydroxide and iron oxide - negative electrode.

charge/discharge cycle: a discharge at the nominal rating of a voltaic cell followed by a full recharge.

constant voltage charging (CVC): a method of charging secondary cells using a constant voltage charger.

constant current charging (CCC): a method of charging secondary cells using a constant current charger.

ampere hour capacity (A h capacity): capacity of an accumulator battery measured in ampere-hours,

usually specified at a certain rate of discharge

5. BATTERIES
5.1 Types of batteries
5.1.1 Only stationary secondary cell batteries are specified in this specification.

5.1.2 Two types of battery are specified in this specification:

a) The lead-acid type (see 5.1.3).

b) The nickel-cadmium alkaline type (see 5.1.4).

5.1.3 The following types of lead-acid battery are specified in this specification:

a) High performance Plante cells generally complying with BS 6290: Parts 1 and 2.
b) Tubular plate cells.
c) Flat plate cells.
d) Sealed cells

5.1.4 The nickel-cadmium batteries specified in this specification are vented pocket plate cells which
are used in:

a) General purpose batteries for standby and infrequent charge/discharge systems.

b) Low resistance batteries for standby systems and those not involving deep and/or regular
discharging.
c) Heavy duty batteries for deep and regular discharging.

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5.2 Characteristics and comparisons of batteries

5.2.1 The lead-acid battery
5.2.1.1 Typical lead-acid battery characteristics are given in Table 1.

TABLE 1 - Typical lead-acid battery characteristics

Type of battery
Characteristics Units High
performance Flat Tubular Sealed
Plante cells plate cells plate cells
Nominal voltage Volts per cell 2 2 2 2
Capacity range at Ampere hours 15 to 2000 15 to 2000 15 to 2000 2.5 to 400
15 0 C at 10 hour rate
Final voltage Volts per cell
after discharge 1.85 1.85 1.85 1.8
at 10 hour rate*
Float voltage Volts per cell 2.25 to 2.3 2.25 to 2.3 2.25 to 2.3 2.25 to 2.3
Boost voltage Volts per cell 2.5 2.5 2.5 **
Maximum voltage Volts per cell 2.7 2.7 2.7 **
Maximum voltage Volts per cell 2.27 2.27 2.27 **
without gassing
Discharge time Hours See Figure 1 See Figure 1 See Figure 1 -
Charging time Hours See Figure 2 See Figure 2 See Figure 2 -
Ampere hour % 90 90 90 -
efficiency
Watt hours 16 000 to 16 000 to 30 000 to 3145 to
Power per m 3 40 000 40 000 70 000 8000
rating Watt hours 10 to 20 10 to 20 20 to 30 1.4 to 3.1
per kg
Weight rating kg per ampere 0.127 to 0.097 to 0.069 to 0.20 to***
hour 0.210 0.144 0.105 0.40
* In accordance with BS 6290: Parts 1 and 2
** Seek manufacturers advice
*** At 400 Ah capacity, weight rating = 0.06 kg Ah −1

5.2.1.2 High performance Plante cells and flat plate cells are not suitable for charge/discharge systems of
operation. Tubular plate cells are recommended for charge/discharge systems.

5.2.1.3 High performance Plante cells can be used in parallel. Cells do not charge and discharge evenly
but they do 'even up' over a period of time.

Tubular and flat plate cells of different ages have different characteristics and are not recommended for use
in parallel. Batteries of the same age may be connected in parallel and should be constant voltage charged.
If trickle charging is used the current will need adjustment to combat the increased open circuit losses due
to ageing.

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5.2.1.4 The life of any lead-acid cell may be reduced if operated at excessive temperatures. Because of
the negative resistance characteristic an increase in the trickle charge current will occur with a rise of
temperature.

5.2.1.5 The life of the batteries is from 4 years up to 10 years with between 150 and 1500
charge/discharge cycles. The number of cycles that can be obtained depends on the depth of discharge,
operating temperature and efficiency of charging equipment.

It should be noted that sealed batteries can gas during incorrect charging and ventilation should be provided
to cater for this situation. The manufacturer should be consulted as to the degree of gassing that can be
expected from a particular battery/charging system, since this will determine the ventilation requirements
(see clause 10). Sealed batteries can be float charged at constant potential. Other methods of charging may
be permissible and the manufacturer should be consulted for details.

5.2.1.6 The life expectancy of various types of lead-acid battery is as follows:

a) high performance Plante cells - 20 years,

b) tubular positive cells - 10 years to 12 years;
c) flat plate cells - l0 years;
d) sealed cells - 4 years to 10 years (see 5.2.1.5).

5.2.1.7 The state of charge of lead-acid cells is indicated by the SG (specific gravity) of the electrolyte.
Lead-acid cells should not be stored in a discharged state.

5.2.1.8 Constant voltage charging of all standby power batteries is recommended to obviate the dangers
of overcharging.

5.2.1.9 Typical recharge times for high performance Plante cells, at a float voltage of 2.25 volts per cell
and a current limit in amperes, equal to the value of 7% of the 10 h ampere hour capacity are given in
Table 2.

TABLE 2 - Typical recharge times for Plante cells

5.2.2 The nickel-cadmium battery

5.2.2.1 Typical nickel-cadmium battery characteristics at a battery electrolyte temperature of 25 0 C are as
given in Table 3.

5.2.2.2 Nickel-cadmium batteries can be stored in any state of charge without resorting to trickle
charging. If batteries are to be stored for a lengthy period, the battery manufacturer should be consulted for
advice.

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5.2.2.3 Nickel-cadmium batteries can be used in parallel. Cells do not charge and discharge evenly but
they do 'even up' over a period of time.

5.2.2.4 The negative resistance characteristic of cells causes an increase in trickle charge current with
increase in temperature. This has no detrimental effect on the cells.

5.2.2.5 The life expectancy of nickel-cadmium cells is 20 years for all types specified in this
specification. Depending on the duty of the battery it may be necessary to change the electrolyte during the
operating life.

5.2.2.6 A discharge test is the only method by which the state of charge can be checked.
Recommendations for this test should be obtained from the relevant battery manufacturer.

5.2.2.7 The typical recharge times, under constant voltage conditions with charge current limited to 0.2
of rated capacity are:

a) Low resistance cells - 76 % in 7 hours; 85% in 10 days at 1.45 volts per cell
b) General purpose cells - 70% in 7 hours; 81 % in 10 days at 1.47 volts per cell.
To fully charge a nickel-cadmium battery under these conditions would take approximately 3 months.

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TABLE 3 - Typical nickel-cadmium battery characteristics

5.2.2.8 As batteries age the recharge times can increase, e.g. approximately 20% in 20 years. Ageing is
influenced by:

a) Depth and frequency of the charge/discharge cycles.

b) Incorrect charging maintenance.
c) Natural deterioration of active material.

NOTE - With a constant current charge of 0.2 of rated capacity approximately 70%
capacity is restored in 5 h and 100% in 7 h.

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EBC1

6. APPLICATIONS
6.1 Applications of batteries and battery containers
6.1.1 Table 4 gives guidance on the types of batteries to be used for various applications.

6.1.2 Table 5 gives guidance on the types of battery containers to be used for various applications.

TABLE 4 - Application of batteries

Application Type of battery

Standby systems
Charge/discharge systems
Switchgear closing
Switchgear opening
Engine starting
Lead-acid
High performance Plante
cells or Sealed cells
Tubular plate cells
Plante cells or Sealed cells
Plante cells or Sealed cells
Plante cells or flat plate cells
or Sealed cells
Nickel-cadmium
General purpose cells or low
resistance cells if standby time is less
than 1 h
Heavy duty cells
Low resistance cells
General purpose cells
Low resistance cells

TABLE 5 - Applications of battery containers (cell enclosure)

6.2 Application of battery and battery charger systems

6.2.1 Battery and battery charger systems shall be designed to suit the load requirements specified in
Appendix A. End cell control as a method of maintaining overall battery performance shall not be used.
Battery tapping to obtain different levels of voltage is not recommended.

6.2.2 Consideration shall be given to the maximum and minimum voltage deviations from nominal that
can be tolerated without causing damage, or the load to operate outside specification. Particular attention
should be given to the output voltage of the battery charging system under boost charge conditions as, due
to operational conditions, it is not always possible to isolate the load.

6.2.3 Where the load is unable to cope with the battery charging system voltage tolerances,
consideration should be given to installing d.c. voltage regulators.

6.2.4 The capacity of the battery should be such that it is capable of supplying the load requirements at
the minimum ambient temperature likely to be encountered in service.

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7. BATTERY CHARGING AND CONTROL EQUIPMENT (EXCLUDING BATTERIES)

7.1 Mode of operation of circuits using constant voltage battery chargers
7.1.1 Battery charging and control equipment shall be suitable for installation in a non-hazardous area
within a ventilated building or other suitable enclosure. The equipment shall be suitable for the specified
environment, e.g. noise level considerations.

7.1.2 The equipment shall be of the constant voltage charge type with automatic control and of such
capacity that under normal conditions it will simultaneously supply the load (see A.3 to A.5 inclusive and
7.1.7) and maintain the battery in a fully charged state. Forced ventilation of the charging equipment shall
not be used unless approved by Transco.

7.1.3 The battery charger shall be of the full wave, semiconductor, constant voltage type. Where
semiconductors are operated in parallel they shall be separately protected.

7.1.4 Any failure of the battery charger or a.c. mains supply shall cause immediate transfer of the load
to the battery without any break in continuity of the output voltage to the load.

7.1.5 Subsequent to an interruption of the a.c. mains supply, the battery charger shall automatically
come into operation upon the resumption of the supply.

7.1.6 A boost charge facility, manually selected by means of a 'Float/Boost' selector switch, lockable in
the 'Float' position, shall be provided. The output of the battery charger shall not exceed the required boost
voltage (see A.5.1). If required by Transco, a separate contact shall be provided on the 'Float/Boost' selector
switch to initiate the continuous running of the battery room ventilation fans when the boost mode is
selected (see A.5.2).

7.1.7 The float voltage shall be as specified in A.8. The charging equipment must be capable of
supplying the standing load and at the same time be able to recharge the battery to full capacity within the
time period specified in A.6.1, after continuous discharge at the standing load current specified in A.6.2 for
the discharge period specified in A.6.3.

7.1.8 Voltage adjustments to float and boost levels shall be provided.

7.1.9 The equipment shall be capable of withstanding the following conditions without suffering
damage or departing from its specified performance:

a) Ambient temperature - 0 0 C to 40 0 C .
b) Relative humidity - up to 95%.

7.1.10 The design operational a.c. supply voltage for the equipment shall be as specified in A.10 and
shall be one of the following:

a) 110 V, 1 phase, 2 wire, 50 Hz.

b) 240 V, 1 phase, 2 wire, 50 Hz.
c) 415 V, 3 phase, 4 wire, 50Hz.

A voltage of ± 10% of nominal and/or a frequency variation of ± 5% of nominal shall not damage the
equipment or cause the output to deviate from the required performance.

Any break in the mains supply, including transients, shall not damage the equipment.

The minimum power factor of the a.c. supply shall be as specified in A.11 and the appropriate equipment to
achieve this shall, if necessary, be provided.

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All busbars, connections and equipment shall be protected, from a.c. and d.c. faults, by suitably rated HRC
(high rupturing capacity) fuses (see 7.3.5).

7.1.11 The equipment shall be capable of operating continuously when complying with the requirements
specified in 7.1.1 to 7.1.10 inclusive and in Appendix A.

7.1.12 The equipment shall be designed so that the intervals between visual inspections are at least 3
months and the intervals between full maintenance checks are at least 12 months.

7.2 Cubicle construction

7.2.1 Each cubicle shall be of the enclosed ventilated type, suitable for indoor use and fabricated from
sheet steel of a thickness not less than 1.5 mm. Mounting shall be as specified in A.12.1.

7.2.2 The cubicle shall afford a degree of protection IP 41 as defined in BS 5420. The degree of
protection shall be proved by suitable testing.

7.2.3 All doors shall have provision for locking, shall be sufficiently rigid to avoid distortion and be
fitted with a seating strip held under compression.

7.2.4 Where specified by Transco in the Technical Schedule (see A.12.3), the preparation and finish of
all steelwork shall comply with PA7.

7.2.5 Adequate lifting facilities shall be provided. Where threaded lifting facilities are provided, the
thread size shall be marked adjacent to the facility.

7.3 Cubicle equipment

7.3.1 Each charger/control unit shall be provided, if specified in the Technical Schedule (see
Appendix A), with the equipment detailed in 7.3.2 to 7.3.10 inclusive.

7.3.2 Main ON/OFF, manually operated, on-load isolating switch for disconnecting the a.c. supply. The
switch shall be capable of breaking not less than full rated current at rated voltage and be suitable for
locking in the OFF position.

7.3.3 Fuses, preferably internally mounted, to isolate the d.c. output in order to work in the charger
without interruption of the d.c. battery load.

7.3.4 Where a battery consists of two sections operated in parallel, suitably rated, manually operated,
interlocked d.c. on-load isolating switches to permit the complete disconnection of either battery 'half'
section from the constant voltage charger unit and the d.c. load. The two switches shall be interlocked with
each other to prevent accidental disconnection of the battery system.

7.3.5 Set of fuses for main control, instrument and distribution feeder circuits (see A.15.4).

7.3.5.1 On earthed systems a fuse/link arrangement shall be used. Where neither pole is earthed, double
pole fusing shall be used.

7.3.5.2 All power fuses, with the exception of semiconductor protection fuses, shall be of the HRC type
in accordance with BS 88 and shall be suitable for 415 V a.c. systems or 240 V d.c. systems and have a
breaking capacity of 40 kA.

7.3.5.3 Where fuses are mounted in withdrawable insulated carriers, the fixed contacts shall be shrouded.

7.3.5.4 Link carriers shall not be interchangeable with fuse carriers.

7.3.5.5 The lengths of connections between the main copperwork and the live side of control circuit and
instrument fuses shall be kept as short as practicable.

7.3.5.6 An indelible label shall be permanently fixed adjacent to each fuse group, stating the rating of the
fuses and the circuits to which they are connected.

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7.3.6 The following indicator lamps shall be provided:

Amber - 'mains failed'

Amber - 'CVC failed'
Blue - 'Boost charge ON'
White - 'Float charge ON'

All indicator lamp fittings shall be adequately ventilated, shall be designed to permit lamp changing from
the front, and their mounting shall be such as to prevent rotation when this is carried out. Operating
voltages of indicator lamps shall not exceed 24 V. Other suitable forms of indication may be used.

7.3.7 The following instruments shall be provided. They should have a scale length not less than 65
mm.

a) Voltmeter, moving coil movement, suitably scaled (charger output).

b) Ammeter, moving coil movement. suitably scaled (charger output).
c) Ammeter, moving coil movement, centre zero, suitably scaled (battery current).

7.3.8 The transformer shall be suitably rated and have an earthed screen between primary and
secondary windings.

7.3.9 Overload protection shall be provided. Where devices which are capable of being reset are used
they shall trip immediately if reset while an overload persists.

7.3.10 Alarms and other relays, as detailed in 7.3.10.1 to 7.3.10.6 inclusive, shall be provided.

7.3.10.1 Charge failure alarm relay pre-set to give immediate warning by a local indicator of failure of the
constant voltage charger and fitted with normally open and normally closed voltage-free contact(s)
connected to a terminal block.

7.3.10.2 Adjustable low output voltage alarm relay fitted with normally open and normally closed voltage-
free contact(s) connected to a terminal block.

7.3.10.3 A load disconnect trip with independently fused supply set to the voltage given in the Technical
Schedule (see Appendix A) and with a reset level above the open circuit voltage of the battery when
tripped.

77.3.10.4 A mains failure alarm relay with a local indicator and fitted with normally open and normally
closed voltage-free contact(s) connected to a terminal block.

7.3.10.5 A high voltage output alarm relay (to indicate control loop faults when in the float mode) fitted
with normally open and normally closed voltage-free contact(s) connected to a terminal block.

7.3.10.6 Earth fault indication relay fitted with normally open and normally closed voltage-free contact(s)
connected to a terminal block.

7.4 Internal wiring

7.4.1 Internal wiring shall be PVC (polyvinyl chloride) insulated and of the appropriate grade and size
to suit circuit parameters. Wiring should be coloured as follows:

a) 3-phase connections (a.c.) - Red, yellow and blue.

b) Neutral connections (a.c.) - Black.
c) Earth connections - Green/yellow.
d) Positive (d.c.) - Red

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e) Negative (d.c.) - Black.

Polarity identification shall be provided on d.c. connections.

7.4.2 The minimum conductor size permissible for power circuits is 1.5 mm 2 cross-sectional area.

7.4.3 Where necessary, wires shall be identified at each end by a sleeve type marker in accordance with
the schematic diagram.

7.4.4 All wiring shall be securely and neatly fixed by means of insulated cleats.

7.5 Cable entry gland plates

7.5.1 Undrilled, detachable cable gland plates shall be provided. The thickness of the plate shall be
such as to prevent distortion when drilled to accept the types of cables specified in A.15 and shall not be
less than 1.5 mm.

7.5.2 Gland plates shall be so positioned as to facilitate top or bottom cable entry as specified in A.14
and to avoid obstruction and interference with the internal equipment.

7.6 Terminals
7.6.1 Terminals for d.c. and a.c. circuits shall be grouped separately.

7.6.2 All terminal blocks shall be fitted with barriers and have separate terminals for incoming and
outgoing connections. Not more than two connections, excluding purpose made interconnectors, shall be
permitted on any one terminal.

7.6.3 Terminal blocks for use with voltages greater than 125 V a.c. and 250 V d.c. shall be suitably
shrouded.

7.6.4 All terminal blocks shall be labelled numerically, in sequence, and grouped according to function
in accordance with the schematic diagram.

7.6.5. Input/output terminals shall be suitable for use with the cables specified in A.15. Rail mounted, non-
pinching type terminals, manufactured from shatter proof material, shall be used for all control and
instrumentation wiring which should be fitted with approved, pre-insulated, crimped terminations.

7.7 Earthing
7.7.1 All non-current-carrying metal work, including the cubicle frame, shall be bonded by means of
green/yellow PVC covered, flexible copper conductors of appropriate size (minimum cross-sectional area
1.5 mm 2 ) to the earth stud or bar.

A non-ferrous earth stud shall be provided for external earthing purposes and, if specified in A.16.3, a main
copper earth bar shall extend the full length of the cubicle.

7.7.2 The positive or negative terminal shall be earthed when specified in A.16.

7.8 Labelling
7.8.1 The cubicle shall be provided with all necessary permanent labels. Warning labels shall be black
lettering on a yellow background and other labels black lettering on a white background. Lettering shall
have a height not less than 6 mm.

7.8.2 External labels shall be fixed by bolting, metal rivetting, or self-tapping screws types D and T to
BS 4174; adhesive shall not be used.

7.8.3 Labels for fitting inside the equipment shall be of non-conducting material and may be fixed with
an adhesive if it can be shown to provide a permanent fixing.

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7.9. Tools
If specified in A.17, a complete set of tools necessary for the maintenance of the equipment shall be
provided.

7.10 Documentation
7.10.1 An operating instruction manual relevant to the equipment shall be provided.

7.10.2 The data specified in A.18 shall be provided with the equipment.

7.10.3 International standard 'A' sizes are preferred for all drawings and documentation.

7.10.4 Transco reserve the right to reproduce any documentation for their own use.

8. COMBINED BATTERY AND BATTERY CHARGING EQUIPMENT

8.1 The use of combined battery charging equipment is not precluded.

8.2 The selection of this type of equipment should be based on the requirements in clause 7.

8.3 The battery shall be in the lower part of the equipment housing with a solid, sealed, dividing sheet
between the battery compartment and the charging control equipment housed in the upper part.

8.4 Connections between the battery and its charging equipment shall be made in a manner which
will prevent the collection of hydrogen within the compartment which houses the charging equipment.

8.5 Ventilation of the battery compartment shall be by louvred openings. The cross-sectional area of
the louvred openings shall be determined using the following formula:

A = V/10
Where:

A = free area of louvred openings in m 2 .

V = volume of battery compartment in m 3 .

8.6 The d.c. output to the load should be fused.

8.7 At least 200 mm space should be allowed over the top of the cells to facilitate topping up.

9. QUALITY SYSTEMS
9.1 The Contractor shall set up and maintain such quality assurance and inspection systems as are
necessary to ensure that goods or services supplied comply in all respects with the requirements of this
specification.

9.2 Transco will assess such systems against the requirements of the applicable parts of BS 5750 and
shall have the right to undertake such surveys as are necessary to ensure that the quality assurance and
inspection systems are satisfactory.

9.3 Transco shall have the right to undertake inspection or testing of the goods or services during any
stage of manufacture at which the quality of the finished goods may be affected and to undertake inspection
or testing of raw materials or purchased components.

10. INSTALLATION OF BATTERY SYSTEMS

10.1 General
10.1.1 Lead-acid batteries and nickel-cadmium alkaline batteries shall not be accommodated in the same
room. Cross contamination of electrolyte, even in small quantities, destroys either battery.

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10.1.2 Installations with more than one type of battery shall have a separate tool kit for each type of
battery. The tool kit should include a hydrometer, thermometer, electrolyte level testing tube, filling funnel,
topping up bottle and a set of standard tools to fit the interconnecting links of the battery.

10.1.3 If batteries are located in a battery compartment, the ventilation of the compartment shall comply
with 8.5.

10.1.4 Batteries for starting engines, turbines and operating switchgear should ideally be installed
adjacent to the equipment to reduce voltage drop to a minimum.

10.1.5 Large battery installations (above 10 000 W h capacity) shall preferably be housed in a room
specifically set aside for that purpose. The room shall contain only the batteries, connections, charging
equipment, fixed lighting installation, fixed heating installation, ventilation system, water supply, medical
equipment, fire extinguishers and other equipment associated with the battery installation. Battery
installations below 10 000 W h capacity may be housed with other equipment.

10.1.6 Battery installations do not normally require automatic fire detection and alarm systems but a
minimum of two hand held fire extinguishers which should hold the equivalent of 1.5 kg BCF
(bromochlorodifluoromethane) or 4.5 kg CO 2 shall be provided (see SFP2).

10.1.7 For practical reasons not every recommendation appropriate to large installations can be applied
to small installations.

10.2 Battery rooms

10.2.1 Battery rooms should be sited so that at least one side forms an outside wall and of such a size
that the battery occupies not more than 10% of the volume of the room.

10.2.2 Doors shall open outwards, be lockable and fitted with a quick release feature for use in an
emergency. There should be two doors, one being located in an outside wall. The door in the outside wall
shall be of such a size as to permit the easily handling of the largest single piece of equipment which may
have to be moved into or out of the room.

Doors and their surrounds should be fire resistant to meet local Fire Authority requirements and should
have at least half hour and preferably a one hour fire rating.

The doors of a battery room should be clearly labelled as follows:

BATTERY ROOM

NO ENTRY FOR UNAUTHORISED PERSONNEL

NO SMOKING

10.2.3 Ideally battery room walls should be constructed of engineering brick or concrete.

10.2.4 The floor shall be designed to support the weight of the batteries (see Tables 1 and 3 for typical
weight of batteries) and should be provided with a drainage channel in case of spillage of electrolyte.
Ideally, for large installations, the floor should be covered with quarrytile, glazed to BS 6431: Part 6 (EN
176), and provided with a similar skirting. Water grout should be acid/alkaline resisting.

10.2.5 Where a quarrytile floor is not fitted the floor shall be treated to reduce dust and finished with an
acid/alkaline resistant surface.

10.2.6 Ceilings having voids above them should not be fitted. If they exist, the void must be ventilated to
the same standard as the battery room.

10.2.7 The overall ventilation system shall be designed to limit the percentage of hydrogen in the air to
1 % (25% LFL).

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10.2.8 The rate of evolution of hydrogen from a battery on charge can be calculated from the formula:

112
.
q = × 10 − 3 nl
26.7
Where:

q = rate of evolution of hydrogen in m 3 /h

n = number of cells
l = charging current in amperes.

Typical values of charging current are as given in Table 6.

TABLE 6 - Typical values of charging current

10.2.9 All battery rooms shall have sufficient natural ventilation to comply with 10.2.7 under float
charge conditions. It is recommended that ventilation is designed on the basis of gas buoyancy, which
requires vents at both high and low level. The total area of the vents at high level shall be equal to that of
the vents at low level and the ventilation area shall be evenly distributed between the external walls.

10.2.10 For battery rooms having four external walls with vents the ventilation area is calculated from the
following formula:

0.24q
A min =
d
Where

A min = Minimum free area of vents at either high or low level in m3

q = Rate of evolution of hydrogen from battery in m 3 /h
d = Vertical distance between high and low level vents in m.

10.2.11 For battery rooms which do not have four external walls with ventilators, the following correction
factors should be applied to the value for A min .

3 external walls with ventilators - multiply by 1.33

2 external walls with ventilators - multiply by 2
2.33
1 external wall with ventilators - multiply by
0.4d

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10.2.12 The position of ventilators should be such as to avoid unventilated pockets of air, e.g. behind
drop beams. If the building has a pitched roof the high level ventilators should be positioned at the apex of
the pitch.

10.2.13 To comply with 10.2.7 under boost charge conditions the rate of air change necessary to ventilate
the battery room sufficiently can be determined from the formula:

Q = 99 q
Where:

Q = rate of air change necessary to ventilate battery room in m 3 /h

q = rate of evolution of hydrogen from battery in m 3 /h.

The air changes should be obtained by:

a) fixed natural ventilation designed to operate effectively under all wind conditions. (The
buoyancy equation of 10.2.10 is not applicable to the high rates of hydrogen evolution when
boost charging).
b) Forced ventilation.
c) Natural ventilation such as opening doors, provided that sufficient control is used to ensure
that the requirements of 10.2.7 are met, i.e. wind speed and direction must be correct and all
necessary vents opened.

See Appendix B for specimen ventilation calculation.

10.2.14 Care must be taken to ensure that air from the battery room is not used to ventilate any other part
of the building and that it is not possible for sufficient hydrogen to accumulate to create a flammable
atmosphere.

10.2.15 Where a forced ventilation system is required it should be designed by a competent heating and
ventilation engineer. Duplicate induced-draught fans should preferably be fitted in the roof or in an outside
wall at high level. To comply with 10.2.14 it is essential that air is extracted from the battery room and
ducted to the outside in order that all inlet air is taken from non-hazardous areas.

10.2.16 Roof ventilators are recommended to achieve all or most of the high level ventilation.

10.2.17 Forced ventilation fans should be powered by motors that are totally enclosed and are unlikely to
spark during starting or normal operation.

10.2.18 Control gear for ventilation fans should be mounted outside the battery room and activated by a
switch adjacent to the personnel access door. Where forced ventilation is required during boost charging,
consideration should be given to operating the fans from the manual boost charge switch of the charging
equipment.

10.2.19 Battery rooms shall be provided with a fixed lighting installation giving sufficient illumination so
that battery maintenance can be carried out without the use of handlamps. Luminaires shall be of robust,
totally enclosed construction and be mounted at a lower level than the bottom of the high level outlet air
ventilators. The provision of luminaires directly over the cells should be avoided. Wherever possible
luminaires should be installed over the access area between the rows of cells.

10.2.20 To maintain optimum battery performance the battery room temperature should not be allowed to
fall below 10 0 C . Where electric heaters are installed they should be of the totally enclosed tubular type,
operating at low surface temperature and fixed approximately 150 mm above floor level. The heaters should
be controlled by a switch having a red neon indicator, clearly labelled 'Heaters', sited at least 750 mm
horizontally from the battery.

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Hot water radiators may be used if a reliable, automatically controlled hot water system is available.

10.2.21 'First Aid' equipment, which should preferably include a main cold water supply of potable
quality or an eye wash apparatus, capable of washing both eyes simultaneously, or sterile saline solution in
disposable containers shall be available in rooms specifically set aside as battery rooms and should be
adjacent to the battery. In the case of small installations the irrigators and saline solution may be carried by
the person servicing the battery.

It is necessary to ensure that the sterile solutions are changed on a regular basis in accordance with the
manufacturer's instructions.

Note - For sealed battery installations this requirement is not essential

10.2.22 A notice, giving instructions as to the treatment of persons suffering from electric shock, shall be
displayed in battery rooms where the battery voltage exceeds 250 V.

10.3 Installation of batteries

10.3.1 Lead-acid batteries are normally delivered to site in a fully charged condition.

10.3.2 Nickel-cadmium batteries are normally delivered to site in an electrically discharged condition.

10.3.3 Where Transco transport batteries in a vehicle, e.g. between maintenance base and operational
site, consideration should be given to the possibility of electrolyte spillage and short circuits due to events
such as sudden braking.

10.3.4 Cells having glass or plastics containers should be handled carefully to prevent damage.

10.3.5 Where possible, cells should be lifted by the shoulders on the sides of the container. Cells shall
not be lifted by the terminal posts. If cells are large or heavy it may be advisable to make lifting frames or
jigs to fit under the shoulders so that two or more operatives may lift the cell.

10.3.6 The cells should be physically disposed so that the potential gradient is, as far as possible, from
one end of the battery to the other. This means that the supply leads will be situated at opposite ends of the
battery.

10.3.7 Consideration should be given to fusing standby batteries as close as possible to the battery
terminals.

10.3.8 Battery leads shall be PVC insulated and suitably marked to identify positive and negative.

10.3.9 The battery connection cables should be suspended vertically above the battery terminations to
relieve mechanical stress on the terminal posts.

10.3.10 Battery leads shall be fitted with cable lugs and bolted to the terminal posts. Terminal posts, tops
of steel enclosed cells and lugs shall be coated with a light smear of petroleum jelly or the battery
manufacturer's recommended grease prior to bolting the battery interconnections.

10.3.11 Cable lugs shall be fixed to leads by soldering (using a non-corrosive flux) or by an approved
crimping method.

If soldered, the PVC insulation shall be cut back 15 mm from the cable lug. After soldering, the cable lug
and surrounding area shall be washed in warm water.

10.3.12 Consideration should be given to covering or insulating the terminals and interconnections of
batteries.

10.3.13 Batteries that are installed adjacent to the equipment being supplied should be housed in
ventilated, hardwood boxes with lids. Any exposed battery terminals and cell interconnections should be
protected with insulation.

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10.3.14 'No smoking' and 'No naked flame' notices shall be displayed adjacent to the batteries together
with instructions supplied with the battery and any other notices considered necessary.

10.4 Preparation of batteries for service

10.4.1 When preparing batteries for service, the manufacturer's detailed instructions should be strictly
observed. The instructions may differ between manufacturers and for this reason the recommendations in
10.4.2 to 10.4.9 inclusive are given only for general guidance.

10.4.2 Where batteries are delivered to site filled with electrolyte of the correct specific gravity, the cell
filler openings are normally sealed to prevent spillage during transit. Prior to putting into service the actions
detailed in 10.4.3 to 10.4.5 inclusive should be carried out.

10.4.3 The filler plugs shall be removed and the sealing feature of the plug removed. A full face mask,
gloves and electrolyte resistant apron shall be worn during this operation as pressure build up, during
transport, may cause electrolyte to spray when the plugs are removed. The operator should consider
removing rings, wrist watches and jewellery to avoid the risk of causing an accidental short circuit.

10.4.4 The electrolyte level in each cell shall be checked and, if it is less than the battery manufacturer's
recommended level above the plates, it shall be topped up with distilled, de-mineralised or other water
approved by the battery manufacturer.

NOTE - If an accident has occurred and it is necessary to fill or top up the battery
with electrolyte, the precautions detailed in 12.2.4 shall be observed.

10.4.5 All cell filler caps shall be inserted, and must remain in situ except when checking levels, taking
specific gravity readings and topping up.

10.4.6 The polarity of all intercell and main connections should be checked.

10.4.7 All intercell connections should be checked for cleanliness and tightness.

10.4.8 Any moisture on the battery should be removed. It should be checked that a light smear of
petroleum jelly or the battery manufacturer's recommended grease, has been applied to all metal parts, i.e.
connections and tops of steel enclosed cells.

10.4.9 All cells, and the complete battery, should be checked to ensure that they are firmly held and
correctly positioned on their stands

11. PRE-SERVICE INSPECTION, CHARGING AND TESTS

11.1 General inspection
11.1.1 The manufacturers' drawings and detailed instruction manuals supplied with batteries and battery
chargers should be studied prior to putting into service all types of batteries and their associated charging
and control gear. All instructions and recommended procedures contained therein should be strictly
observed.

11.1.2 A general inspection of the completed battery and charging installation should be carried out by
the commissioning engineer to ensure that the installation fully complies with the requirements specified in
this specification. Particular care should be taken to ensure that safety precautions have not been
inadvertently nullified, e.g. ventilation fans rotating in the wrong direction.

11.2 Inspection and test of charging and control equipment

11.2.1 A complete examination of the charging equipment should be carried out to ensure that all
external wiring has been correctly sized and connected according to the drawings.

11.2.2 All electrical connections shall be checked for tightness and security.

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11.2.3 All cables should be checked for correct colour coding and numbered markers which should
correspond with the numbers on the external connection terminal blocks.

11.2.4 All 'live' terminal guards shall be correctly fitted.

11.2.5 Ensure that an indelible label has been fixed adjacent to each fuse group and that the rating of all
HRC fuse links complies with the charging/control equipment manufacturer's recommendations.

11.2.6 Isolator/door mechanical interlocks, if fitted, should be checked for correct operation.

11.2.7 An insulation test to earth should be carried out on the a.c. side of the battery charger. Special
precautions must be taken if the secondary side of the battery charger transformer is tested.

11.2.8 Tests should be carried out on all earthed metalwork and earth protection systems in accordance
with the IEE Regulations for Electrical Installations.

11.3 Inspection and charging of batteries

11.3.1 General
11.3.1.1 The SG* of the electrolyte and the voltage of each cell shall be checked, recorded and compared
with the battery manufacturers' published figures.
* The SG of the electrolyte varies with the temperature. Any reading on the hydrometer should therefore be corrected as follows:
- For each 1.50C above 150C, add 1 point (0.001 SG) to the reading on the hydrometer.
- For each 1.50C below 150C. subtract 1 point (0.001 SG) from the reading on the hydrometer.
The equivalent correction (Fahrenheit temperature scale) is 1 point (0.001 SG) for every 2.50F above or below 590F.

11.3.1.2 If artificial ventilation of the battery room is necessary, it shall be switched on (see 10.2.16).

11.3.1.3 The battery should be put on charge using the boost charge facility at a current in accordance with
the battery manufacturer's instructions.

11.3.1.4 The installation should be supervised during the initial boost charge and frequent inspection of
the battery and charging equipment should be made for any sign of excessive temperature rise.

11.3.2 Charging lead-acid batteries

11.3.2.1 Select a minimum of two cells, well separated, as 'pilot' cells. Variations in the SG value of the
electrolyte in the 'pilot' cells from the nominal SG value for a fully charged battery will be indicative of the
state of charge of the whole battery.

11.3.2.2 Boost charging should be continuous, taking SG and voltage readings on the 'pilot' cells at hourly
intervals, until the readings become constant over a period of 3 h. During the boost charge the temperature
of the electrolyte shall not be allowed to exceed 38 0 C .

11.3.2.3 During boost charging when the individual cell voltages reach 2.3 V the charging current shall
not exceed the finishing rate of charge, i.e. current in amperes shall not exceed the value of 7% of the 10 h
ampere hour capacity of the battery.

11.3.2.4 When the battery has reached the fully charged condition the SG of the electrolyte and the voltage
of each cell should again be checked and recorded. It should be ensured that all electrolyte levels are
correct.

11.3.2.5 At the end of the boost charge, the battery shall be switched to the float charge operation.

11.3.2.6 Any moisture on the battery should be removed, and it is recommended that all metal parts, i.e.
connections and tops of steel encased cells, be protected with a light smear of petroleum jelly or the battery
manufacturer's recommended grease.

11.3.3 Charging nickel-cadmium batteries

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11.3.3.1 The SG of the electrolyte of nickel-cadmium cells does not vary with the state of charge of the
cell but gradually falls during service.

11.3.3.2 During the boost charge regular checks should be made to ascertain electrolyte levels and
electrolyte temperature. The temperature of the electrolyte shall not be allowed to exceed 45 0 C .

11.3.3.3 At the end of the boost charge, the battery charger shall be switched to the float charge condition.

11.3.3.4 Any moisture on the battery should be removed and it is recommended that all metal parts, i.e.
connections and tops of steel encased cells, are protected with a light smear of petroleum jelly or the battery
manufacturer's recommended grease.

11.4 Final battery installation check with load connected

11.4.1 The battery charging equipment should be checked for correct operation under load conditions.

11.4.2 All instrument readings on the battery charger should be verified.

11.4.3 All indication and alarm circuits should be tested and proved.

11.4.4 Battery load connections should be checked for heating caused by high resistance joints.

12. BATTERY MAINTENANCE

12.1 General requirements
12.1.1 The general rules given in 12.1.2 to 12.1.8 inclusive should be observed during battery
maintenance.

12.1.2 It is of the utmost importance that batteries and battery chargers are maintained strictly in
accordance with the manufacturers' instructions. Consideration should also be given to the siting and
importance of the battery installation. If the environmental conditions are poor or if failure of the battery
would lead to an unacceptable situation arising, the frequency and quality of maintenance may have to be
increased.

12.1.3 Protective clothing, including a full face-screen or gas-tight goggles complying with BS 2092,
gloves and an electrolyte-resistant apron, are to be provided and worn for all maintenance work involving
contact with electrolyte. The operator should consider removing rings, wrist watches and jewellery to avoid
the risk of causing an accidental short circuit.

12.1.4 All tools used on batteries and in battery rooms shall be of the fully insulated type Floor cleansing
mops and brushes should have wooden shafts.

12.1.5 All connections, vent plugs and fixing bolts shall be kept tight.

12.1.6 The floor shall be kept clean at all times and free from rubbish and litter.

12.1.7 All maintenance action, including pilot cell readings shall be recorded in a log book.

12.1.8 Batteries can be stored satisfactorily provided that they are filled with electrolyte to the correct
level and kept in a clean, dry and cool place. The vent caps shall be kept closed. Batteries must not be
covered with any form of moisture proof sheeting as deterioration of the metal parts could occur due to a
build up of condensation.

Lead-acid batteries should only be stored in a fully charged state and they should be recharged at intervals
not exceeding 3 months.

12.1.9 A regular check of charging current is not necessary; the important factor is the maintenance of
the correct charging voltage at the battery terminals. The charging current will then be self-regulating in
accordance with the state of charge of the battery.

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12.1.10 The electrolyte must be maintained at the correct level.

12.1.11 It is essential that containers, sampling and topping up equipment, previously used in conjunction
with lead-acid batteries, shall not be used with nickel-cadmium cells or vice versa.

Sampling and topping up equipment, e.g. tubes and funnels, must be clean and uncontaminated.

The electrolyte level should be maintained by topping up, as required, with distilled, de-mineralised or
other water approved by the battery manufacturer.

Topping up water should be stored in clean, uncontaminated, glass or polyethylene containers. Metal
containers must not be used.

12.1.12 After topping up, any water spilt must be mopped up immediately and the battery cleaned and
dried. A light smear of petroleum jelly, or the battery manufacturers' recommended grease, should then be
applied to all metal parts.

12.2 Lead-acid battery maintenance

12.2.1 The SG of the electrolyte in lead-acid cells varies with the state of charge and is also affected by
temperature variations, see 11.3.1.1.

The values of SG measured should be compared with those specified by the battery manufacturer when
checking the condition of the battery.

12.2.2 Representative values of SG to be expected with electrolytes at a temperature of l5 0 C are given in

Table 7

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TABLE 7 - Typical SG values for lead-acid cells at 15 0 C

12.2.3 Lead-acid cells in good condition will yield clear electrolyte free of particles in suspension and
produce high SG readings. To avoid incorrect hydrometer readings, readings should not be taken
immediately after topping up; at least 30 min charging is required, after topping up, to ensure correct
hydrometer readings.

12.2.4 During the life of a lead-acid battery it should not be necessary to change the electrolyte.
However, if electrolyte is accidentally spilled from cells, the cells must be refilled as soon as possible with
electrolyte only; water must not be used. When making up the electrolyte it is essential that the sulphuric
acid is added to the water, not the water to the acid. The acid used should meet the requirements of BS
3031, and the water should be to BS 4974, Grade A.

12.2.5 If acid is accidentally spilled, it can be neutralised by wiping the affected area with a lint free
cloth moistened with a dilute alkali e.g. ammonia solution.

12.2.6 If it is necessary to dispose of battery electrolyte the procedure detailed in 12.4 shall be followed.

NOTE - Persons purchasing spent batteries from Transco for disposal/reclamation

should be warned of the dangers or risks involved in disposal.

12.3 Nickel-cadmium battery maintenance

12.3.1 The SG of the electrolyte of standard nickel-cadmium cells, when new, is approximately 1.200 at
a temperature of 20 0 C , with the solution at the correct level. Manufacturers of some 'high electrolyte
reserve cells' (i.e. cells containing a larger than standard volume of electrolyte to reduce the need for
topping up) often recommend electrolyte with an SG in the range of 1.151 to 1.165. It is essential that the
correct electrolyte is used and if this is not known the battery manufacturer should be consulted.

12.3.2 The SG of the electrolyte should be checked every 6 months. When the SG of the electrolyte of
standard cells has fallen to approximately 1.155, at a temperature 20 0 C , the entire electrolyte should be
replaced. If the battery has been kept topped up and correctly maintained, a fall to an SG value of 1.155
should not occur within 5 years.

12.3.3 In no circumstances should the SG of standard or 'high electrolyte reserve cells' be allowed to fall
below 1.145 at a temperature 20 0 C .

12.3.4 If electrolyte is accidentally spilled from cells, the cells must be re-filled as soon as possible with
electrolyte only: water must not be used.

12.3.5 When it is necessary to change the electrolyte, the battery should first be discharged at its normal
rate until the voltage per cell has fallen to 0.8 V. This should take about 5 h and is best accomplished using
a fixed resistance of adequate thermal rating.

The electrolyte should then be emptied from the cells into a suitable container. Cells should be allowed
adequate time to completely drain. In no circumstances should cells be washed out with water.

Each cell should then be re-filled, to the correct level, with new electrolyte, as specified by the
manufacturer.

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The outside of the cells should then be cleaned and dried and the battery re-connected and checked in
accordance with 10.4.6 to 10.4.9 inclusive.

The battery should then be charged in accordance with the manufacturer's instructions.

12.3.6 Electrolyte can be obtained from battery manufacturers in two forms:

a) liquid of the correct SG;

b) crystals to which water should be added, as directed by the manufacturer.

It is essential that suitable protective clothing is worn when mixing and decanting the electrolyte.

12.3.7 If it is necessary to dispose of battery electrolyte the procedure detailed in 12.4 shall be followed.

12.4 Disposal of battery electrolyte

12.4.1 When it is necessary to dispose of battery electrolyte it shall be analysed to determine whether it
is a notifiable waste. It is not possible to quote the degree of contamination that constitutes a notifiable
waste as different Water Authorities specify different levels of contamination.

12.4.2 If the electrolyte is a notifiable waste it shall be:

a) disposed of in a manner and on a site approved by the relevant Water Authority, or

b) disposed of by a commercial waste treatment company.

12.4.3 If the electrolyte is not a notifiable waste, the local Water Authority should be contacted for
advice, i.e. they may accept discharge to sewers if the quantity of electrolyte is small and it has been
diluted.

NOTE - Persons purchasing spent batteries from Transco for disposal/reclamation

should be warned of the dangers or risks involved in disposal.

12.5 Sealed batteries

These batteries are stated by manufacturers as being 'maintenance free'. However, until more experience is
gained in their service and reliability it is recommended that periodic inspection and any necessary
maintenance be carried out at six monthly intervals. It should be noted that the battery charger should be
checked and maintained at the same frequency as for conventional lead acid batteries being float charged.

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FIGURE 1 - Typical A h capacity / discharge time characteristics of lead-acid Plante cells

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FIGURE 2 - Typical charge characteristics (at 15 0 C) of lead-acid Planté cells

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FIGURE 3 - Typical charge characteristics of lead-acid Plante cells at constant voltage

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FIGURE 4 - Discharge characteristics (A h capacity / discharge time) for nickel-cadmium cells

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FIGURE 5 - Charge characteristics for nickel-cadmium cells

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APPENDIX A
TECHNICAL SCHEDULE FOR BATTERIES AND BATTERY CHARGER SYSTEMS TO TRANSCO
SPECIFICATION EBC1

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APPENDIX B
SPECIMEN VENTILATION CALCULATION

B.1 GENERAL
To determine the ventilation requirements for a 240 V, 500 Ah capacity battery installed in a room
6 m x 5 m x 2.5 m high, use formula specified in either B.2 or B.3 as appropriate.

B.2 LEAD-ACID BATTERY

From 10.2.8, rate of hydrogen during float charging in m 3 /h:

112
.
q= x 10 −3 n l
26.7

112
.
q= x 10 −3 x 120 x (0.3 x 500 + 70) x 10 −3
26.7

112
.
= x 120 x 220 x 10 −6
26.7

= 0.011 m 3 /h

If lower vents are at a mean height of 0.5 m from floor level and upper vents are in the ceiling which has no
void above, then d = 2 m.

From 10.2.10, minimum vent area at low level = minimum vent area at high level:

0.24 x 0.011 2
= m
2
= 0.00187 m 2
= 1870 mm 2

This area should be distributed over all four walls at high and low level, i.e. 470 mm 2 at high and low level
in each wall.

For battery rooms which do not have four external walls with ventilators the correction factors given in
10.2.11 shall be applied as follows:

a) For a building with only three outside walls then the ventilation area should be 1.33 x 1870,
i.e. 830 mm 2 at high and low level in each outside wall.
b) For each two outside walls the corresponding ventilation areas should be 1870 mm 2
c) For one outside wall the corresponding ventilation should be 4870 mm 2

From BS 493 the size and number of air bricks indicated in table B.1 would be suitable for the low level
ventilation.

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TABLE B.1 - Air bricks suitable for low level ventilation of lead acid battery installations

Number of Ventilation area Air brick size Air brick free area Number of
outside walls required bricks required
mm 2 mm mm 2
4 470 200 x 75 1100 1
3 830 200 x 75 1100 1
2 1870 300 x 100 2400 1
1 4870 225 x 150 2580 2

In each case ventilators of the same free area would also be required in the roof.

Rate of evolution of hydrogen when boost charging:

112
.
q= x 10 −3 x 120 x (0.07 x 500)
26.7
= 1.76 m 3 /h

Air change rate required to ventilate battery:

Q = 99 q = 99 x 1.76
= 174 m 3 /h

Volume of room = 6 x 5 x 2.5 = 75 m 3

Volume of battery = 120 x 0.23 x 0.368 x 0.592 = 6 m 3

Volume of air in room = 69 m 3

∴Air changes required = 2.53 changes/h.

B.3 NICKEL-CADMIUM BATTERY

From 10.2.8, hydrogen evolved in float charging:

112
.
q= x 10 −3 n l
26.7
112
.
q= x 10 −3 x 200 x (2 x 500) x 10 −3
26.7
= 0.08 m 3 /h

If lower vents are at a mean height of 0.5 m from floor level and upper vents are in the ceiling which has no
voids above, then d = 2m.

J025 (Rev 11/02) - 37 -

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From 10.2.10, minimum vent area at low level = minimum vent area at high level:

0.24 x 0.08 2
= m
2
= 0.014 m 2
= 14 000 mm 2

This area should be distributed over all four walls at high and low level, i.e. 3500 mm 2 at high and low
level in each wall. For battery rooms which do not have four external walls with ventilators the correction
factors given in 10.2.11 shall be applied as follows:

a) for a building with three outside walls the ventilation area should be 1.33 x 14 000,
i.e. 6 200 mm 2 at high and low level in each outside wall.
b) For each of two outside walls the corresponding ventilation areas should be 14 000 mm 2
c) For one outside wall the corresponding ventilation areas should be 36 500 mm 2

From BS 493 the size and number of air bricks indicated in Table B.2 would be suitable for the low level
ventilation.

TABLE B.2 - Air bricks suitable for low level ventilation of nickel-cadmium battery installations

Number of Ventilation area Air brick size Air brick free area Number of
outside walls required bricks required
mm 2 mm mm 2
4 3 500 225 x 225 4 500 1
3 6 200 200 x 200 3 200 2
2 14 000 300 x 300 7 700 2
1 36 500 300 x 300 7 700 5

In each case ventilators of the same free area would also be required in the roof.

Rate of evolution of hydrogen when boost charging:

112
.
q= x 10 −3 x 120 x (0.1 x 500)
26.7
= 4.19 m 3 /h.

Air change rate required to ventilate battery:

Q = 99 q = 99 x 4.19
= 415 m 3 /h

Volume of room = 6 x 5 x 2.5 = 75 m 3

Volume of battery = 200 x 0.416 x 0.156 x 0.158 = 2 m 3

- 38 - J025 (Rev 11/02)

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Volume of air in room = 73 m 3

∴Air changes required = 5.69 changes/h.

J025 (Rev 11/02) - 39 -

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APPENDIX C
RELATED DOCUMENTS
C.1 INFORMATION ON RELATED DOCUMENTS
The documents listed below are not specifically referred to in the text of this specification but their subjects
relate to the equipment covered by this specification. These references are given in this appendix as sources
of technical information which may be of use and interest to Transco personnel concerned with batteries,
battery chargers and associated control equipment.

C.2 BRITISH STANDARDS

BS 905 - Sound and television broadcast receivers and associated equipment:
electromagnetic compatibility:
Part 1 - Specification for limits of radio interference
Part 2 - Specification for limits of immunity

BS 4417 - Semiconductor rectifier equipments

C.3 ELECTRICITY COUNCIL PUBLICATIONS

Engineering - Limits for harmonics in the UK electricity supply system*
recommendation
G5/3

ACE Report - Harmonic distortion caused by converter equipment

No. 15
* Obtainable from the Electricity Association

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