This client needed to replace their 25 year old C&D wet cell battery systems in two locations. They were both 48vdc telecom systems. Existing Lorain chargers were reconnected after the battery replacement was complete. EnerSys PowerSafe DDm batteries were used to replace the old C&D wet cells. Thorough IEEE-1188 inspections were done with an Alber Cellcorder CRT-400 and acceptance capacity (load) testing was completed as well with an Alber DC Load bank and BCT-2000.
Archive for: Battery Load Testing
At this chemical processing plant, two new switchgear systems were added to support new operations. Two new 120vdc Enersys Varta NiCd battery strings were designed and installed to back up these switchgear. The project included Enviroguard Hawk Spill Containment systems, racks, Hindle AT-10 chargers and 92 NiCd cells in each string. An Alber MPM-100 battery monitoring systems was added as well to each string. Battery was also discharged to confirm its capacity from the factory. An Alber DC resistive load bank was used in concert with a BCT-2000 to record the battery performance.
In 2005, API installed and commissioned the client’s Alber BDS-256 battery monitoring system on 14 battery strings. Every year, API conducts capacity (load) testing and thermal infrared scanning services on all critical battery systems. For each capacity test, the battery’s discharge and performance data is captured with the BDS-256 and a comprehensive report is provided. API also performs quarterly preventative maintenance on the client’s Alber BDS-256 battery monitoring systems to ensure proper operation and that it is calibrated to factory specifications.
At this datacenter facility, API removed and recycled two strings (80 total jars) of VRLA batteries and then installed new Enersys DataSafe 12HX-400 batteries for the client’s UPS. Four spare batteries were also removed and installed. After the battery replacement and proper charging, an IEEE-1188 inspection was conducted prior to commissioning the battery strings with an acceptance test. During the acceptance testing, an Alber Battery Capacity Test Set (BCT) and Alber DC Resistive Load bank were used to discharge and capture the battery performance data. API also conducts annual preventative maintenance on this datacenter’s Alber Battery Monitoring Systems.
API was responsible for providing a new rack, as well as the replacement battery cells. All batteries were replaced — two parallel strings with four 6-cell modules per string, supplying a nominal 48VDC. (2x4x12). Battery installed was EnerSys model 12HX-400. All posts, intercell connectors and terminal lugs were prepared and cleaned using a light coating of “No-Ox” to prevent corrosion. Using an insulated torque wrench, all connections were verified per the manufacturer’s recommendations. After installation, voltage values were verified and the rectifier and telephone system were restarted.
This private power utility hired API to provide a turnkey solution to retrofit their legacy backup power systems. A new battery building was purchased and outfitted for each of the three substations. After the first substation was complete, the other two followed suit.
New distribution feeds were required to be ran from the existing generator cabs as well. After installation, the batteries were acceptance (load) tested and the power loads were transferred to the new system. Later, the old batteries were de-commissioned and properly recycled.
This long time client has tasked API with several preventative maintenance services. From UPS to battery maintenance, they trust API to take care of their backup power systems to ensure zero downtime. In 2010, several batteries were replaced, including a UPS string. Enersys Genesis XE95 Pure Lead cells (red and black cells shown above) were used on one of three UPS strings. The client also has a Telecom room which we test and maintain.
This datacenter contracted API to conduct its comprehensive UPS battery maintenance and battery replacement program. As their VRLA battery systems are replaced, am acceptance load test is conducted after the installation to properly commission the new battery string. A regimented quarterly IEEE-1188 battery maintenance inspection is conducted on every string to ensure this datacenter’s operations and uptime are never compromised. They are proud users of Enersys DataSafe HX VRLA and DataSafe DX batteries.
This client contracted API to conduct capacity (load) testing on its two UPS VLA battery strings. Two 120-volt Alber DC Resistive load banks were connected in series to test these two 480v UPS Vented Lead Acid strings. An Alber BCT-2000 was utilized to capture the battery’s performance data during the discharge test.
This critical datacenter site consists of seven VLA battery strings and API conducts quarterly IEEE-450 battery preventative maintenance. Every quarter both voltage and internal resistance levels are reported on every individual cell. On an annual level, specific gravity is also taken.