Version: 3.0
Date: 30/01/2017
DC Supplies and Common Services Test Form
Substation NameSubstation Number
Circuit
Batteries
Purpose / Manufacturer / Cell Reference / Nominal Voltage (V) / No of Cells / Capacity (Ah)
Close trip and alarm
Telecontrol
Intertrip
LOPI
Battery Chargers
Purpose / Manufacturer / Type / Serial Number / Output
Float / Boost
A / V / A / V
Close trip and alarm
Telecontrol
Intertrip
LOPI
LV Auxiliary Supply Fail Relay
Manufacturer / Type / Phases / Voltage
Fire Equipment
Manufacturer / Type / Number of Cylinders / Number of Sections
Commissioning Tests
Commissioning shall follow the stages listed below. All detailed test results shall be recorded on the sheets provided at the rear of this Schedule.
Where battery commissioning is carried out by the Battery/Charger Contractor, the tests shall be based on the requirements of this Schedule but may follow the Contractor's procedures.
Stage 1 – After Erection of Battery, Charger and Switchboard and Connection of AC Supply to Charger, but Before Equipment is Required for Use
Objective - to ensure erection is carried out satisfactorily and that working equipment is available for Stage 2 tests; also to maintain the battery charge level until required for service.
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Check erection of battery, charger and switchboard and interconnection of same
Measure and record individual cell terminal voltages and specific gravities (where appropriate) of battery 'as received', before charger is connected and switched on
Check presence and value of all fuses
Check insulation to earth of battery connections, using 1000V megger
Check insulation to earth of charger and switchboard, using 1000V megger. Advise Commissioning Engineer if any drying out required
Check AC supply fuse and connections to Charger, and that correct supply is available
Check that Charger operates normally in both 'float' and 'boost' outputs. Record 'float' and 'boost' charger voltages and currents. (This does not necessitate carrying out the functional tests required in stage 2.)
At the end of these tests the charger is to be left in the 'Float' position with an AC supply on
Note: If it is not practicable to maintain the Battery on continuous float charge between stages 1 and 2, agreement shall be reached with the Battery Manufacturer on the procedure to be adopted.
No discharge shall be taken from the battery prior to Stage 2.
Stage 2 - When DC Supply System is Complete and Immediately Prior to Placing into Service
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Ensure that the battery is in a charged condition prior to commencement of tests. This can be checked by reading the specific gravity of electrolyte in one cell, or for sealed cells, by reading the terminal voltage with charger 'off' and no load
Repeat Stage 1 test (5), unless Stages 1 and 2 are carried out concurrently when there will be no necessity to repeat
(For Plante cells only) Top up battery, if necessary, with distilled water. De-mineralised water may be used subject to approval by the battery manufacturer
Connect load equivalent to approximately 50% of charger rating and, with charger switched off, check that battery discharges correctly into it (instrument polarities correct, etc.) also that low voltage alarm relay operates. Discharge need not exceed 10-15 minutes
Switch charger on and to 'float'. Check charger attains full rated output (this rate may last for a short time only if Battery is in a fully charged condition) and that current-limit feature operates
Switch charger to 'boost' and, with load still connected, check that full rated output is obtainable. Note that maximum charger output may only persist for a short time before tapering down
Note, for sealed gas recombination cells, 'boost' charging must be kept to the minimum period
Switch charger back to 'float' position and, with load still connected, check that DC standing voltage is within limits required by the specification. Remove load, and check that voltage remains within limit
The correct 'float' voltage is carefully set-up and locked during test at the charger manufacturer's works, and should not normally require adjustment on-site
Check operating voltage of low voltage, charger fail (abnormal) and high voltage alarm relays. Record values on forms attached.
Check operation of earth fault detector by connecting each pole of the system to earth in turn, via a 47k resistor
(For Plante cells only) Disconnect load, switch charger to 'boost', and continue until battery is fully charged. Then record specific gravity and voltage of each cell (with charging current still flowing)
(For all cell designs) Switch charger to 'float' and leave. It is important that an AC supply to the charger shall be maintained continuously from this point onwards, and the charger left in the 'float' position in order to keep the battery fully charged. Record all cell or monoblock terminal voltages on the form attached
Note, on some chargers the 'float' output may be labelled 'normal', whilst the 'boost' output may be selected on some by means of change over links inside, and on others by means of a switch either on the front or inside
Test operation of substation auxiliary supply fail relay, by reducing each phase input voltage in turn, and record operating voltages.
Check operation of telecontrol Alarm
Test operation of fire Protection equipment telecontrol alarm (where fitted)
Type / Purpose / Date
Cell Temperature / C / Cell Temperature / C
SG Correction Factor / SG Correction Factor
BATTERY AS-RECEIVED / BATTERY AS-RECEIVED
Cell / SG / V / Cell / SG / V / Cell / SG / V / Cell / SG / V
1 / 31 / 1 / 31
2 / 32 / 2 / 32
3 / 33 / 3 / 33
4 / 34 / 4 / 34
5 / 35 / 5 / 35
6 / 36 / 6 / 36
7 / 37 / 7 / 37
8 / 38 / 8 / 38
9 / 39 / 9 / 39
10 / 40 / 10 / 40
11 / 41 / 11 / 41
12 / 42 / 12 / 42
13 / 43 / 13 / 43
14 / 44 / 14 / 44
15 / 45 / 15 / 45
16 / 46 / 16 / 46
17 / 47 / 17 / 47
18 / 48 / 18 / 48
19 / 49 / 19 / 49
20 / 50 / 20 / 50
21 / 51 / 21 / 51
22 / 52 / 22 / 52
23 / 53 / 23 / 53
24 / 54 / 24 / 54
25 / 55 / 25 / 55
26 / 56 / 26 / 56
27 / 57 / 27 / 57
28 / 58 / 28 / 58
29 / 59 / 29 / 59
30 / 60 / 30 / 60
Initial charger checks / Check battery polarity / ()
Switch charger to float, check output / A / V
Switch charger to boost, check output / A / V
Type / Purpose / Date
Cell Temperature / C / Cell Temperature / C
SG Correction Factor / SG Correction Factor
BATTERY AS-RECEIVED / BATTERY AS-RECEIVED
Cell / SG / V / Cell / SG / V / Cell / SG / V / Cell / SG / V
1 / 31 / 1 / 31
2 / 32 / 2 / 32
3 / 33 / 3 / 33
4 / 34 / 4 / 34
5 / 35 / 5 / 35
6 / 36 / 6 / 36
7 / 37 / 7 / 37
8 / 38 / 8 / 38
9 / 39 / 9 / 39
10 / 40 / 10 / 40
11 / 41 / 11 / 41
12 / 42 / 12 / 42
13 / 43 / 13 / 43
14 / 44 / 14 / 44
15 / 45 / 15 / 45
16 / 46 / 16 / 46
17 / 47 / 17 / 47
18 / 48 / 18 / 48
19 / 49 / 19 / 49
20 / 50 / 20 / 50
21 / 51 / 21 / 51
22 / 52 / 22 / 52
23 / 53 / 23 / 53
24 / 54 / 24 / 54
25 / 55 / 25 / 55
26 / 56 / 26 / 56
27 / 57 / 27 / 57
28 / 58 / 28 / 58
29 / 59 / 29 / 59
30 / 60 / 30 / 60
Initial charger checks / Check battery polarity / ()
Switch charger to float, check output / A / V
Switch charger to boost, check output / A / V
Type / Purpose / Date
Cell Temperature / C / Cell Temperature / C
SG Correction Factor / SG Correction Factor
BATTERY AS-RECEIVED / BATTERY AS-RECEIVED
Cell / SG / V / Cell / SG / V / Cell / SG / V / Cell / SG / V
1 / 31 / 1 / 31
2 / 32 / 2 / 32
3 / 33 / 3 / 33
4 / 34 / 4 / 34
5 / 35 / 5 / 35
6 / 36 / 6 / 36
7 / 37 / 7 / 37
8 / 38 / 8 / 38
9 / 39 / 9 / 39
10 / 40 / 10 / 40
11 / 41 / 11 / 41
12 / 42 / 12 / 42
13 / 43 / 13 / 43
14 / 44 / 14 / 44
15 / 45 / 15 / 45
16 / 46 / 16 / 46
17 / 47 / 17 / 47
18 / 48 / 18 / 48
19 / 49 / 19 / 49
20 / 50 / 20 / 50
21 / 51 / 21 / 51
22 / 52 / 22 / 52
23 / 53 / 23 / 53
24 / 54 / 24 / 54
25 / 55 / 25 / 55
26 / 56 / 26 / 56
27 / 57 / 27 / 57
28 / 58 / 28 / 58
29 / 59 / 29 / 59
30 / 60 / 30 / 60
Initial charger checks / Check battery polarity / ()
Switch charger to float, check output / A / V
Switch charger to boost, check output / A / V
DC Circuits
Insulation Tests 1000V Megger
Disconnect Circuits from battery and charger.
Battery Supply to Charger DC Board or Remote DC Board
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Closing (Solenoid) Supplies – Section 1
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Closing (Solenoid) Supplies – Section 2
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Trip and Close Alarm Supplies – Section 1 (Transformers)
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Trip and Close Alarm Supplies – Section 2 (Transformers)
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Trip and Close Alarm Supplies – Section 1 (Feeders)
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Trip and Close Alarm Supplies – Section 2 (Feeders)
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Other Supplies (e.g. Auto Switching or Tap Change Control Common DC Supply)
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Cable Low Oil Pressure Circuits – Battery Supplies / Number 1 Circuit / Number 2 Circuit
DC polarity check / () / ()
Fuse rating and link proved for correct function / () / ()
Insulation resistance between cores / MΩ / MΩ
Insulation resistance positive to earth / MΩ / MΩ
Insulation resistance negative to earth / MΩ / MΩ
Intertrip Circuits – Battery Supplies / Number 1 Circuit / Number 2 Circuit
DC polarity check / () / ()
Fuse rating and link proved for correct function / () / ()
Insulation resistance between cores / MΩ / MΩ
Insulation resistance positive to earth / MΩ / MΩ
Insulation resistance negative to earth / MΩ / MΩ
Charger Circuits
It is recommended that tests to detect possible earth faults on the charger be carried out in such a way as to include as much of the dc circuitry as practicable.
For batteries that are 'unearthed' and not fitted with a Battery Earth Fault Alarm detection circuit, under healthy conditions a Voltmeter connected from battery terminals to earth should indicate either no, or a very low value, of standing voltage. If significant readings are obtained, then the lower voltage indicates the leaky or faulty pole.
Where a Battery Earth Fault Alarm is installed, this will effectively place a high-impedance earth connection on the centre-point of the battery, so that under healthy conditions each battery pole will be at approximately half battery voltage to Earth. If the readings are greatly different, then the lower voltage indicates the leaky or faulty pole.
Battery Purpose
DC voltages measured from:
Positive terminal to earth / V / V / V
Negative terminal to earth / V / V / V
Telecontrol 48V Battery Supplies
Ensure terminal equipment e.g. outstation is disconnected at remote end before carrying out insulation tests.
Switchgear Marshalling Cabinet Supplies
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Tap Change Marshalling Cabinet Supplies
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Channelling Equipment Supplies
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
Data Concentrator and/or Outstation Supplies
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
PAX Supplies
DC polarity check / ()
Fuse rating and link proved for correct function / ()
Insulation resistance between cores / MΩ
Insulation resistance positive to earth / MΩ
Insulation resistance negative to earth / MΩ
110V Battery
High volt alarm / Setting 128V / Operates at / V
High volt alarm time delay (1-5s nominal) / ()
Low volt alarm (switchgear to BS 116) / Setting 94V / Operates at / V
Low volt alarm (switchgear to BS 5311/IEC 56) / Setting 100V / Operates at / V
Low volt alarm time delay 20-50ms / ()
Charger fail alarm / Setting 118V / Operates at / V
Charger fail alarm time delay (1-5s nominal) / ()
48V Battery
High volt alarm / Setting 56V / Operates at / V
High volt alarm time delay (1-5s nominal) / ()
Low volt alarm / Setting 47V / Operates at / V
Charger fail alarm / Setting 51V / Operates at / V
Charger fail alarm time delay (1-5s nominal) / ()
Battery Alarm Circuits (with marshalling cabinet links open)
Insulation Resistance / 110V Battery / 48V Battery
High volt alarm / between cores / X37-X2 / M / M
to earth / X37-E / M / M
Low volt alarm / between cores / X45-X2 / M / M
to earth / X45-E / M / M
Charger fail alarm / between cores / X51-X2 / M / M
to earth / X51-E / M / M
Common to earth / X2-E / M / M
Common to earth / W2-E / M / M
Alarm Checks / 110V Battery / 48V Battery
Check receipt of alarm signal at marshalling cabinet links / Low volt alarm / () / ()
High volt alarm / () / ()
Charger fail alarm / () / ()
Substation LV Supply Monitoring (Auxiliary Supply Fail)
Auxiliary Supply Fail Relay / Phase Reduced / Voltage
Setting / Operating
With normal voltages supplied check output relay energised. Next reduce voltage of each phase in turn and note voltage at which output relay de-energises / Red
Yellow
Blue
Supply Fail Alarm Circuit
Ensure marshalling cabinet links are open
Insulation resistance between cores / X57-X2 / M
Insulation resistance to earth / X57-E / M
Check alarm received at marshalling cabinet link / ()
Fire Protection Alarm
Ensure marshalling cabinet links are open
Insulation resistance between cores / X35-X2 / M
Insulation resistance to earth / X35-E / M
Check alarm received at marshalling cabinet link / ()
Comments
Test Equipment
Purpose / Make/Type / Serial Number
Certification / ()
Attach manufacturer’s specific tests (if applicable)
All tests have been completed satisfactorily
Contractor Commissioning Engineer (if applicable)
Organisation / Name
Date / Signature
UK Power Networks Commissioning Engineer
Name / Signature / Date
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