SAUDI ARAMCO ID/PID - 03/01/05 - REV 0 (Standards Cutoff - August 2004)

SATR NUMBER DATE APPROVED QR NUMBER

SAUDI ARAMCO TEST REPORT
UPS/DC Vented Lead-Acid Wet Cell, Jobsite Acceptance
SATR-P-3103 1-Oct-05 ELECT-
Test
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

A. TEST PROCEDURE AND CHECKLIST

The initial battery capacity test and commissioning records are pertinent
to the maintenance and optimum operational life of the battery. All
commissioning data shall be dated, recorded, and maintained in a
permanent file to facilitate required future maintenance and interpretation
of the operating data. The following data shall be maintained in a
permanent record file: SAES-P-103
A1
a. Initial battery capacity test performed in accordance with IEEE 450 (for Sec. 10.1
lead acid), IEEE 1106 (for nickel cadmium), or IEEE 1188 (for VRLA) as
applicable.
b. The initial resistance values of the intercell connections.
c. The initial individual cell voltages and specific gravity measurements.

Check that the Vented lead-acid cells are meeting the design, 17-SAMSS-511
A2 performance, and test requirements of IEC 896-1. Sec. 8
Perform an acceptance and initial commissioning test as per the
referenced IEEE Standards on all batteries at the job site. Batteries will 17-SAMSS-511
A3
be prepared and charged in accordance with manufacturer's Sec. 16.2.2
recommendations.
Check that the electrolyte level of each cell is between the high and low IEEE Std 450
A4
level marks imprinted on the cell case. Annex E (d)
Check thoroughly each battery cell jar, cell jar cover, and seal (jar-to-
IEEE Std 450
A5 cover seal, post-to-cover seal) for deterioration (cracking, crazing-
Annex E (e)
spiderweb effect, distortion, etc.).
IEEE Std 450
A6 Check thoroughly the plates in each cell for sulphation.
Annex E (f)

Check the plates in each cell for the proper color that indicates a fully IEEE Std 450
A7
charged battery based on the manufacturer’s information. Annex E (g)
Check through, the clear battery jar case, the plates, the bus bar
connection to each plate, and the bus bar connection to the post of each
IEEE Std 450
A8 battery cell for corrosion and other abnormalities. Inspect the lower part
Annex E (h)
of the post seals and the underside of the cover for cracking or distortion.

IEEE Std 450

A9 Check that all cells of the battery are properly numbered.
Annex E (l)

Check that each battery cell vent, flame arrestor, and dust cap is present IEEE Std 450
A10
and inspect each for damage. Annex E (m)

Perform test that Batteries are delivering a minimum 90% of their rated
ampere-hour capacity at the initial site-commissioning test. Batteries 17-SAMSS-511
A11
delivering less than 90% of the rated capacity need to be returned to the Sec. 16.2.2
vendor for replacement.

If resistance readings obtained are more than 20% above the installation
IEEE Std 450
A12 value or above a ceiling value established by the manufacturer, or if
Sec. 4.4.1.C
loose connections are noted, retorque and retest.

Page 1 of 6
SAUDI ARAMCO ID/PID - 03/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
UPS/DC Vented Lead-Acid Wet Cell, Jobsite Acceptance
SATR-P-3103 1-Oct-05 ELECT-
Test
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.
Initial conditions:
Equalize the battery if recommended by the manufacturer and then IEEE Std 450
A13
return it to float for a minimum of 72 h, but less than 30 days, prior to the Sec. 6.1 a
start of the test.
Check all battery connections and ensure that all resistance readings are IEEE Std 450
A14
correct for the system. Sec. 6.1 b

Record the specific gravity and float voltage of each cell just prior to the IEEE Std 450
A15
test. Sec. 6.1 c

Record the electrolyte temperature of 10% or more of the cells to IEEE Std 450
A16
establish an average temperature (suggested every sixth cell). Sec. 6.1 d

IEEE Std 450

A17 Record the battery terminal float voltage.
Sec. 6.1 e

Take adequate precautions (such as isolating the battery to be tested

IEEE Std 450
A18 from other batteries and critical loads) to ensure that a failure will not
Sec. 6.1 f
jeopardize other systems or equipment.
Test length:
The recommended procedure is to perform a capacity test for
approximately the same length of time for which the battery was sized.
IEEE Std 450
A19 When the battery is required to supply varying loads for specified time
Sec. 6.2
periods (a load duty cycle), the performance test may not substantiate
the battery’s capability to meet all design loads, particularly if very-high-
rate, short-duration loads determine the battery size.
Test discharge rate:
The discharge rate depends upon the type of test selected. For the
acceptance test or performance test, the discharge rate should be a IEEE Std 450
A20
constant current or constant power load equal to the manufacturer’s Sec. 6.3
rating of the battery for the selected test length.

Acceptance, modified performance, and performance tests:

a) Disconnect the charging source, connect the load bank to the battery,
start the timing, and continue to maintain the selected discharge rate. If IEEE Std 450
A21
the charging source cannot be disconnected, the current being drawn by Sec. 6.4 a
the load must be increased to compensate for the current being supplied
by the charging source to the battery.
Maintain the discharge rate until the battery terminal voltage decreases
IEEE Std 450
A22 to a value equal to the minimum average voltage per cell as specified by
Sec. 6.4 b
the design of the installation (e.g., 1.75 Vdc) times the number of cells.
Read and record the individual cell voltages and the battery terminal
voltage. The readings should be taken while the load is applied at the IEEE Std 450
A23
beginning of the test, at specified intervals, and at the completion of the Sec. 6.4 c
test. There should be a minimum of three sets of readings.
If one or more cells is approaching reversal of its polarity (+1 V or less)
IEEE Std 450
A24 and the test nears the 90–95% expected completion time, continue the
Sec. 6.4 d
test until the specified terminal voltage is reached.
If earlier in the test an individual cell is approaching reversal of its
IEEE Std 450
A25 polarity (+1 V or less) but the terminal voltage has not yet reached its
Sec. 6.4 e
test limit, the test should be stopped.

IEEE Std 450

A26 Observe the battery for intercell connector heating.
Sec. 6.4 f
Restoration:
IEEE Std 450
A27 Disconnect all test apparatus. Recharge the battery and return it to
Sec. 6.7
normal service.

Page 2 of 6
SAUDI ARAMCO ID/PID - 03/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
UPS/DC Vented Lead-Acid Wet Cell, Jobsite Acceptance
SATR-P-3103 1-Oct-05 ELECT-
Test
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

Specific gravity readings are based on a temperature of 77°F (25°C).

The readings should be corrected for the actual electrolyte temperature IEEE Std 450
A28
and level (see A.3). For each 3°F (1.67°C) above 77°F, add 1 point Annex A 2
(0.001) to the reading. Subtract 1 point for each 3°F below 77°F.
Effect of electrolyte level:
The specific gravity of the electrolyte in a cell will increase with a loss of
water due to electrolysis or evaporation. When specific gravity readings
are being taken, the electrolyte levels should also be measured and
recorded. The battery manufacturer will provide a gravity correction IEEE Std 450
A29
factor for the particular cells involved. However, if the electrolyte level is Annex A 3
between the high and low level marks and the temperature corrected
specific gravity of the electrolyte is within the manufacturer’s nominal
specific gravity range, it is not necessary to correct the specific gravity of
the battery for electrolyte level.

Effect of water additions:

When water is added to a cell, it tends to float on top of the electrolyte
because its specific gravity is 1.000 in comparison to 1.215 nominal for
the electrolyte in most batteries. If the cells are in a normal float charge
condition, there is very little mixing of the electrolyte due to gassing. In IEEE Std 450
A30
certain cell types it may take 6–8 weeks or longer for complete mixing to Annex A 4
occur. The specific gravity should be read before adding water, or
the battery should be given an equalizing charge after the water has
been added. The battery should be back on normal float voltage for 72 h
before the specific gravity is measured after an equalizing charge.

Test all post-to-post and terminal connections for proper resistance after PE 1-2003
A31
all terminal connections are completed and prior to use of the battery. Sec. 2.5.10

B. TEST EQUIPMENT AND MATERIALS CRITERIA

1. Ranges of measuring devices: The instruments used shall enable the values of voltage and current to be measured. The caliber of these
instruments and the measuring methods shall be chosen so as to ensure the accuracy specified for each test. For analogue instruments this implies
that readings shall be taken in the last third of the graduated scale. (Ref: IEC 60896-11, Sec. 12.1.1)

2. Voltage measurement: The instruments used for voltage measurement shall be voltmeters of an accuracy class equal to 0,5 or better. The
resistance of the voltmeters used shall be at least 1 k Ω/V. See IEC 60051or IEC 60485. (Ref: IEC 60896-11, Sec. 12.1.2)
3. Current measurement: The instruments used for current measurement shall be ammeters of an accuracy class equal to 0,5 or better. The entire
assembly of ammeter, shunt and leads shall be of an accuracy class of 0,5 or better. See IEC 60051 or refer to IEC 60359. (Ref: IEC 60896-11, Sec.
12.1.3)
4. Temperature measurement: For measuring temperature, thermometers shall be used having a suitable measuring range in which the value of each
graduated division is not in excess of 1 °C. The absolute accuracy of the instruments shall be at least 1 °C. (Ref: IEC 60896-11, Sec. 12.2)

5. Electrolyte density measurement: For measuring electrolyte densities, hydrometers or other instruments shall be used with scales so graduated
that the value of each division is not in excess of 5 kg/m3. The absolute accuracy of the instruments shall be at least 5 kg/m3. (Ref: IEC 60896-11,
Sec. 12.3)

6. Time measurement: For measurement of time, the instruments’ accuracy shall be ±1% or better. (Ref: IEC 60896-11, Sec. 12.4)

C. TEST RESULTS

Page 3 of 6
SAUDI ARAMCO ID/PID - 03/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
UPS/DC Vented Lead-Acid Wet Cell, Jobsite Acceptance
SATR-P-3103 1-Oct-05 ELECT-
Test
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

D. CONCLUSIONS

ITEM
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

D1

D2

D3

Test results are acceptable and in accordance with Saudi Aramco

D4 N/A
Engineering Standards and contractual requirements.

REMARKS:

REFERENCE DOCUMENTS:
1. SAES-P-103 UPS and DC Systems 28 April, 2004
2. NEMA PE 1 Uninterruptible Power Systems (UPS) - Specification and Performance Verification (1-2003)
3. IEEE Std 450 Vented Lead-Acid Batteries for Stationary Applications Edition 1995
4. 17-SAMSS-511 Stationary Storage batteries 28 April, 2004
NOTES:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the manufacturer
indicates compliance with appropriate standards or performance in a specified manner.

Page 4 of 6
SAUDI ARAMCO ID/PID - 03/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
UPS/DC Vented Lead-Acid Wet Cell, Jobsite Acceptance
SATR-P-3103 1-Oct-05 ELECT-
Test
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
No.

Contractor / Third-Party Saudi Aramco

Technician Performing Test* PMT Representative
Name, Title, Department, Test Performed Successfully and Results are Acceptable: T&I Witnessed QC Record Reviewed Work Verified
Company, Initials and Name, Initials and Date:
Date:
QC Inspector PID Representative
Witnessed Test Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Implementation of Test and Analysis of Results Y = YES N = NO F = FAILED

Page 5 of 6
SAUDI ARAMCO ID/PID - 03/01/05 - REV 0 (Standards Cutoff - August 2004)
SATR NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO TEST REPORT
UPS/DC Vented Lead-Acid Wet Cell, Jobsite Acceptance
SATR-P-3103 1-Oct-05 ELECT-
Test
Attachment 1 -IEC 60896-11

Page 6 of 6