ML20217Q795

Revised Maint Procedures,Including Rev 0 to MP 755.3, Battery Cell Connections Maint & Ductoring, Rev 0 to Maint Form 755.3-1 & Rev 0 to Maint Form 755.3-2

ML20217Q795
Person / Time
Site:	Millstone
Issue date:	08/26/1997
From:	NORTHEAST NUCLEAR ENERGY CO.
To:
References
PROC-970826, NUDOCS 9709030364
Download: ML20217Q795 (38)

Text

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l NDS Document Transmittal #03161 8/26/97 To:

Nuclear Regulatory Commission Aodressee uniques 140 Document Control Desk ROUTINE distribution Washington, D.C. 20555 The following documents have been revised. You are currantly on distribution for these documents. Verify that all documents are included in this distribution set.

DOCUMENT REY COPIES 755.3-1 0

1 755.3-2 0

1 MP 755.3 0

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DR ADOCK 05000245 PDR Retum this form to NDS, MP475,3rd Floor. C/O Rick Lundin (x2446) as soon as received.

Signature Date:

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k MILLSTONE NUCLEAR POWER STATION MAINTENANCE PROCEDliRE Battery Cell Connections Maintenance and Ductoring MP 755.3 f

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,s Approval:

K3 PORC Mtg. No:

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9 25-99 Effective Date:

8 el(o-97 Level of Use SME: M. De General

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Maintenance Procedure Battery Cell Connections Maintenance and Ductoring 4

l TABLE OF CONTENTS 1._

PURPOSE....................................................2 2.

P RE R EQ UI S ITES.............................................

3 :

3.

P R E CAUTI O N S...............................................

6

- 4.

I NSTRU CTI O NS.............................................

7

- 4.1 In-Service Cell Connection Cuaning and Inspection...........

7

'4.2 Ductor Battery Cell Connections-Initial Installation o r Be n ch m a rk............................................

9 4.3 Ductor Battery Cell Connections-Normal Maintenance......

14 4

4.4 -

Disassembly, Cleaning, and Inspection of Cell Connections.....

19 4.5 Assembly of Cell Connections.............................

22

! D) 5.

REVIEW AN D SIG N-OFF....................................

25

- - iw 6.

R E FE R E NCES...............................................

25

-7.

.. S UM M ARY O F CHANG ES............. -......................., 25 ATTACHMENTS AND FORMS,Intercell Connection (Post-to-Post Measurement)"..

26

.," Cable Connections (Lug-to-Post Measurement)"..... 27 Maint Form 755.3-1," Battery Connections Ductor Readings" Maint. Form 755.3-2, " Battery Connections Ductor Reading)s - Gas 1brbine Battery (For Normal Maintenance Ductoring "

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1. PURPOSE J

1.1 Objective The purpose of this procedure is to provide instructions for lead-acid battery cell connection maintenance and ductoring.

1.2 Discussion This procedure provides instructions for the following:

Limited cleaning of posts during in-service battery operation Disassembly, cleaning, and assembly of battery cell connections a

including intercell (bar-type) and cable connections Ductoring connections for new battery installation or to establish a set of benchmark resistance values Duetoring connections for normal preventive maintenance (such as an annual PM)

The ductoring portion of this procedure contains instructions for (n'f establishing a set of benchmark data upon new battery installation or when no existing benchmark data exists. The benchmark data is a set of resistance values of alllike-connections that fall within 10 percent of each other. Once the benchmark data is established, future normal maintenance ductor readings may be campared against it. The normal maintenance ductor reading for a particular connection must fall within 20 percent of the benchmark resistance for that connection; othenvise the connection must be disassembled and cleaned.

When benchmark data for a particular battery is known, the acceptance criteria (benchmark + 20%) has been calculated and added to the maintenance form. In instances where no existing installation benchmark data exists, Enrineering or the battery manufactuwr must provide the ductoring acc-mee criteria (a maximum resistance for each type of similar conne-i on the battery).

The Assembly of Cell Connections section may be used to assemble connections during a new battery installation.

1.3 Applicability This procedure applies to all 24-volt and 125-volt lead-acid batteries.

O MP 755.3 Level of Use STOP THINX ACT REVIEW Rev.0 General 2 0f 27

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2. PRERiiOUISITES n)

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2.1 General 2.1.1 An AWO has been prepared and approved by Operations Department.

2.1.2 Battery room ventilation or heating system is operable and free of obstructions,if applicable.

2.1.3 Eyewash is provided within vicinity of the battery.

2.2 Measuring and Test Equipment (M&TE) 2.2.1 All M&TE has been calibrated in accordance with WC 8,

" Control and Calibration of Measuring and Test Equipment" and the calibration is current.

2.2.2 OA torque wrenches (click or dial type) with a minimum accuracy and maximum torque wrench full scale value listed in the table below for the specified torque application range:

Specified lbrque Maximum Torque Wrench c

(a)

Application Range Full Scale Value Minunm Accuracy 150 to 157 in-lbs between 200 and 700 in-lbs 5%

j 100 to 105 in-lbs between 150 and 450 in-lbs 5%

2.2.3 Biddle ductor low-resistance ohmmeter with ranges of 0 - 6 milliohms,0 - 60 milliohms, and 0 - 600 milliohms, and a minimum accuracy of 1% plus one lea.;t significant digit t

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2.3 Tools and Consumables O

2.3.1 Tools Electrician's standaid tool kit 2.3.2 Equipment Acid-resistant apron Acid-resistant gloves Face shield Goggles llot plate or heat gun (for grease application)

Insulated flashlight Soft-bristle brush 2.3.3 Consumables O

Approved oxide inhibitor or cotrosion resistant oil such as NO-OX -ID A grease Baking soda for neutralizing solution (one pound baking soda per gallon demineralized water)

Demineralized water Fine-grit abrasive Low-lint cloths t

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2.3.4 Spare Parts U

NOTE The following kit numbers are for GNB batteries only. The dash number after the battery modelindicates the number of pittes per cell. Kits contain enough connectors and hardware to connect a six-cell row.

Hardware is stainless steel and includes bolts and nuts (5/16-18UNC) and flat washers. Engineering should be consulted befomrdering specific kits.

Intercell C nnector Battery Cell Type Terminal Plate Kit Cable Kit 2-MCX-5 None Required K17-418044 K17-418022 MCX-9 None Required K17-41SO44 K17-418028 NCX-35 K17-418027 K17-418050 K17-418058 2.4 Defnitions 2.4.1 Intercell connection-connection composed of one or more bars

'j that connect the positive post (s) of one cell to the negative post (s) of the adjacent cell 2.4.2 Connection resistance-resistance measurement as measured from cell post to other connection point (i.e., other cell post, cable lug) 2.4.3 Inter-tier connection-connection composed of cable (s) that connect the last cell in a string of cells to a cell in another tier (or step) of cells, on the same battery rack 2.4.4 Inter-rack connection-connection composed of cable (s) that connect a cell in one battery rack to a cell in another rack 2.4.5 Battery terminal connections--cable connections at the endmost positive and negative cell posts 2.4.6 Average intercell connection resistance - total of all intercell connection resistance measurements for the entire battery divided by the number of intercell resistances measured n

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,m 2.4.7 Benchmark-set of resistance values on which future testing may

,(j be based. Resistances must be established in accordance with instructions in Section 4.2.

2.4.8 BURNISil-to make shiny or lustrous by rubbing

3. ERECAUTIONS 3.1 Smoking, flames, or other sources of ignition are not permitted while working in proximity to or on batteries.

3.2 Do not allow any metal objects to short across the battery connections.

3.3 Insulate all working tools.

3.4 Protective clothing (safety glasses, face shield, acid-resistant gloves, and acid-resistant apron)is required when cleaning corrosion from battery connections.

3.5 When battery room is equipped with hydrogen meters, safe entry into battery room is indicated by a maximum hydrogen concentration of less than or equal to 2% hydrogen.

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3.6 Ensure that no objects or cleaning solutions enter battery cell internals.

U 3.7 Neutralize acid spills with a solution of sodium bicarbonate (baking soda).

Never use ammonia, soda ash, sodium hydroxide, or any strong alkalies.

If alkalies are inadvertently spilled on the containers, they should be immediately washed off with water. Flushing and neutralizing spilled electrolyte shall be prohibited without proper equipment.

OV MP 755.3 Level of Use STOP THINK ACT REVIEW Rev.0 General 6of27

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4. INSTRUCTIONS O

4.1 In-Service Cell Connection Cleaning and Inspection STOP WARNING STOP Approved face shields, goggles, acid-resistant gloves, and acid-resistant aprons, along with a long-sleeved shirt, must be worn while maintenance on batteries is being performed.

4.1.1

-DON protective clothing and equipment.

C AUTIO N Terminals and cell connectors are lead-coated. Care must be used not to remove lead coating during cleaning process.

4.1.2 Using clean rags or plastic bristle brush dampened with demineralized water or neutralizing solution, WIPE battery acid buildup and loose corrosion from the following:

Battery cells Terminal posts Intercell and inter-tier connectors 4.1.3 IE neutralizing solution was used, WIPE components and surfaces with demineralized water.

4.1.4 Using clean, low-lint cloths, DRY cells, posts, and connectors thoroughly.

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4.1.5 Visually INSPECT cells and terminal posts for the following:

Physical damage Deterioration Dirt Acid buildup 4.1.6 E inspection results are not satisfactory, CONSULT FLS.

C A O i 10 N

% avoid applying torque to battery terminal posts, two insulated wrenches must be used.

NOTE Both bolt head and nut of stainless steel hardware must be torqued to the n

prescribed torque value. Torquing only one side will not provide the

.V desired tightness.

4.1.7 E loose connections are identified during cleaning or inspection, using two insulated wrenches, TORQUE both bolt head and nut of loose connections to the following values:

Battery Torque (in-lbs)

Station 18A &l8B 150 (150 to 157)

Gas Arbine --

100 (100 to 105)

Neutron Monitoring System 100 (100 to 105) 4.1.8 E necessary, apply anti-corrosion grease to connections and cell posts.

MP 755.3 Level of Use ggggg STOP THINK ACT REVIEW Rev.0 S of 27

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4.2 Ductor Battery Cell Connections-Initial Installation or Benchmark V

NOTE The following section is to be perform'ed just after initial battery installation to establish a set of benchmark data. The purpose of this

. section is to achieve a set of resistance measurements that fall within 10 percent of each other. Once established, future resistance readings for an

- mdividual connection may(be compared against its installation val ue,=and aconsistent tolerance value usually 20 percent) can be used for determining connection integrity. This section may also be used to establish a new set of benchmark data when none exists provided Engineering has been consulted.

4.2.1 RECORD battery identit'ication number and all measurements on Maint. Form 755.3-1.

4.2.2 PREPARE maintenance form for data recording as follows:

a.

Refer 1b Table - 3, "Intercell Connection Resistance Measurements," on maintenance form, and for all inter-tier and inter-rack connection locations RECORD "NA" in adjacent columns.

b.

IE any battery cell is jumpered, DOCUMENT chaage in

" Comments" section and MARK Table - 3 as necessary.

C A U TIO N-1.

Ductoring across a battery cell will damage ductor.

2.

Ductor measurements for intercell connections must be taken from cell post-to-cell post, not from connection hardware or intercell connectors (bars). Attachment 1 provides illustrations for standard measuring techmque required for ductoring :m !nple-post cells.

4.2.3 PERFORM the following forintercell connections:

a.

IE battery is isolated, Refer To Attachment 1, DUCTOR intercell connections, and RECORD each resistance measurement in Table - 3,"Intercell Connection Resistance Measurements," as " FINAL" on maintenance form.

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MP 755.3 Level of Use Rev.0 STOP THINK ACT REVIEW bened 9 0f 27 t-

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E battery is not isolated, Refer To Attachment I ane

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RECORD each resistance measurement in Table - 3, "Intercell Connection Resistance Measurements," on maintenance form as follows:

1) DUCTOR and RECORD first ductor measurement.

2) REVERSE polarity of ductor.

3) DUCTOR and RECORD second ductor measurement.

4) AVERAGE the first and second measurements and RECORD final ductor value, c.

CALCULATE average intercell resistance for battery as follows:

1) ADD all resistance measurements and RECORD as

" Total of all intercell resistance measurements."

2) COUNT number of resistance measurements recorded and RECORD as " Number of measurements recorded."

(b'

3) DIVIDE " Total of all intercell resistance measurements" by " Number of measurements recorded" and RECORD as " Average intercell resistance."

d.

DETERMINE acceptance criteria as follows:

1) MULTIPLY average intercell resistance by 0.1 (10%) and PERFORM applicable action:

E 10 percent of average intercell resistance is less than DR equal to 5 microhms, ADD 5 microhms to average intercell resistance and RECORD as "Intercell Connection Resistance Acceptance Criteria."

E 10 percent of average intercell resistance is greater than 5 microhms, ADD the 10 percent value to average intercell resistance and RECORD as "Intercell Connection Resistance Acceptance Criteria."

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Refer 1b Table - 3,"Intercell Connection Resistance (m")

Measurements," on maintenance form, and INDICATE (circle) any resistance measurements that are greater than the acceptance criteria, f.

E any resistance measurement is greater than "Intercell Connection Resistance Acceptance Criteria" PERFORM the following for non-conforming connection (s):

1) Refer 1b Sections 4.4 and 4.5, and CLEAN and ASSEMBLE connection (s).

2) DUCTOR reassembled intercell connection (s).

3) E any resistance is still greater than "Intercell Connection Resistance Acceptance Criteria," CONSULT Engineering for direction.

NOTE 1.

Ductor measurements for cable connections must be taken from lug-to-post. Attachment 2 provides illustrations for standard measuring technique required for ductoring various types of (7,}

multi-cabled connections.

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2.

Acceptance criteria for cable connections is established for each group of similar type connections (ie, six cables attached using terminal plates to two posts, one cable attached directly to cell post, one cable attached to two cell posts using a terminal plate). Therefore, the acceptable resistance for one type of cable connection may differ from other types of cable connections.

4.2.4 PERFORM the following for cable connections:

a.

OBSERVE types of cable connections including number of cables and use of terminal plates, gV Level of Use MP 755.3 STOP THINK ACT REVIEW Rev.0 General 11 of 27

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9-NOTE l

- Figure - 1 provides an example of marking up maintenance form.

b.

IE all cable connections are not of a similar type, Refer 'Ib Table - 4," Cable Connections Resistance Measurements,"

on maintenance form and in the first column under the cell location, INDICATE which type of connection is represented at that location.

Figure - 1. Marking Thble to Indicate Cable Connection lype - Used in Determining Acceptance Criteria Terminal 1

56 Connection ]

b@h 28 28 (left post)

(right post)

. inter-rack %

Connection J9

}gp (left post)

(righ post) eco-c.

Refer To Attachment 2, DUCTOR cable connections (lug-to-post), and RECORD each resistance measurement in 111bie - 4, " Cable Connections Resistance Measurements."

d.

CALCULATE average cable connection resistance for each type of connection as follows:

1) ADD all resistance measurements for a similar type cable connection and RECORD as " Total of all cable resistance measurements."

2) COUNT number of resistance measurements recorded-for that type of connection, and RECORD as " Number of measurements recorded."

3). DIVIDE " Total of all cable resistance measurements" by

" Number of measurements recorded" and RECORD as

" Average cable connection resistance."

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4) E all cable connections are not of a similar type, Refer

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% maintenance form and INDICATE the type of i

connection represented by value recorded in step 4.2.4.d.3), and REPEAT step 4.2.4.d. for each type of cable connection, c.

DETERMINE cable connection acceptance criteria as follows:

1) MULTIPLY " Average cable connection resistance" by 0.1 (10%) and PERFORM applicable action:

E 10 percent of average cable connection resistance is less than QR equal to 5 microhms, ADD 5 microhms to " Average cable connection resistance,"

and RECORD as " Cable Connection Resistance Acceptance Criteria."

E 10 percent of average cable connection resistance isgreater than 5 microhms, ADD the 10 percent value to " Average cable connection resistance," and RECORD as " Cable Connection Resistance Acceptance Criteria."

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2) E all cable connections are not of a similar type, Refer To step 4.2.4.e. for other connection !ypes.

4 f.

Refer To Table - 4," Cable ConnNtions Resistance Measurements" on maat:c. ann form, and INDICATE (circle) any resistance measurements tha are greater than the acceptance criteria for associated connection type.

g.

E any individual resistance measurement for a particular cable connection type is greater than acceptance criteria for that connection type, PERFORM the following on y

non-conforming connection (s):

1) Refer To Sections 4.4 and 4.5, and CLEAN and ASSEMBLE connection (s).

2) DUCTOR reassembled connection (s).

3) E any resistance is still greater than " Cable Connection Resistance Acceptance Criteria," CONSULT Engineering for direction.

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4.3 Ductor Battery Cell Connections-Normal Maintenance NOTE The following section is to be performed when comparing a new set of-ic ductor readings to the established benchmark or Engineering-approved

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acceptance enteria. This section may also be performed when ductoring only one or a few suspected faulty connections.

4.3.1 RECORD battery identification number and all measurements on the applicable maintenance fctm:

Maint. Form 755.3-1 for station and neutron monitoring

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~ system batteries Maint. Form 755.3-2 for gas turbine battery 4.3.2 IE a full set of ductor readings is being recorded, PREPARE maintenance form for data recording as follows:

a.

Refer To Table - 3, "Intercell Connection Resistance i

Mensurements" on maintenance form, and RECORD "NA" in " Resistance (pp)" column for all inter-tier and inter-rack connection locations.

b.

IE any battery cell is jumpered, DOCUMLNT char.;e in

" Comments" section and MARK Table - 3, as necessary.

th MP 755.3 Level of Use 8"

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t-4 C A UTIO N Ductoring across a battery cell will damage ductor.

NOTE Ductor measurements for intercell connections must be taken from cell ost-to-cell post, not from connection hardware or intercell connectors p(bars)iqu required for duct ri

. Attachment 1 provides illustrations for standard measuring techn e

o ng multiple-post cells.

4.3.3 PERFORM the following forintercellconnections:

a.

E battery is isolated, Refer To Attachment 1 and DUCTOR intercell connections, and RECORD each resistance measurement in Table -'3,"Intercell Connection Resistance Measurements," as " FINAL" on maintenance form, b.

E battely is nor isolated, Refer To Attachment 1 and RECORD cach resistance measuremert in Table - 3, "Intercell Connection Resistance Mcasurements," on -

maintenance form as follows:

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1) DUCTOR and RECORD first ductor measurement.

2) REVERSE polarity of ductor.

3) DUCTOR and RECORD second ductor measurement.

4) AVERAGE the first and second measurements and l

RECORD final ductor value, MP 755.3 Level of Use ST P THINK ACT REVIEW Rev.0 Genemi 15 0f 27

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NOTE v

In the following step,d in accordance with instructions in Section 4.2. This installation (benchmark) data relates to a set of resistances establishe data should be provided by Engineering or FLS. In some instances the acceptance criteria has been precalculated for each connection (benchmark plus 20% tolerance) and recorded on the maintenance form.

E using installation (benchmark) date to compare existing c.

readings against, MULTIPLY the corresponding benchmark resistances by 1.2 and RECORD as " Acceptance Criteria" in applicable row in Table - 3.

d.

LE using a marimmn resistance value based on Engineering-approved or manufacturer data, RECORD m".ximum resistance,alue as " Acceptance Criteria"in applicable row in Table - 3.

c.

E any measured connection resistance is greater than its

" Acceptance Criteria," Refer To Table - 2, " Battery Cell Connection Torque Values" on maintenance form, and TORQUE nonconforming connection to applicable torque value and PERFORM the following:

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1) DUCTOR intercell connection and RECORD new resistance measurement in Table - 3, "Intercell Connection Resistance Measurements," on maintenance form.

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NOTE D

lt may not be necessary to remake a connection that does not fall within 20 percent of the benchmark value when the manufacturer's maximum resistance for that connection is'well above its current value. Engineering should make this decision.

2) E any resistance measurement is stillgreater than its

" Acceptance Criteria," PERFORM applicable action:

E using installation (benchmark) data to compare existing readings against, CONSUlff' Engineering for direction to disassemble and clean the connection.

E using a maximum resistance value based on Engineering-apprc,ed or manufacturer data, Refer To Sections 4.4 and 4.5, and CLEAN and DUC10R connection (s)

E subsequent disassembly and cleaning of connection does not bring satisfactory resistance results, CONSULT FLS or Engineering for further direction.

NOTE Ductor measurements for cable connections must be taken from lug-to-post. Attachment 2 provides illustrations for standard measuring technique required for ductoring various types of multi-cabled connections.

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4.3.4 PERFORM the following for cable connections:

a.

E battery is isolated, Refer 7b Attachment 2, D!ICTOR intercell connections, and RECORD cach resistance measurement in Table - 4," Cable Connections Resistance Measurements," as " FINAL" on maintenance form.

b.

E battery is not isolated, Refer To Attachment 1 and RECORD cach resistance measurement in Table - 3, "Intercell Connection Resistance Measurements," on maintenance form as follows:

1) DUCTOR and RECORD first ductor measurement.

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.g 2)1 REVERSE polarity of ductor.

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3) DUCTOR and RECORD second ductor measurement.

4)- AVERAGE the first and second measurements and RECORD final ductor value, c.

DETERMINE cable connection acceptance criteria as follows:

1) E using a maximum resistance value based on Engineering-approved or manufacturer's data, RECORD this value as " Cable Connection Resistance

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Acceptance Criteria," on maintenance form and Go'Ib step 4.3.4.d.

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2) REQUEST Engineering Department provide the l

l benchmark value for each type of cable connection being ductored.

3) MULTIPLY benchmark value by 1.2 and RECORD as

" Cable Connection Resistance Acceptance Criteria."

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d.

E any resistance measurement is greate: than acceptance criteria, PERFORM the following:

1) Refer 'Ib Table - 2, " Battery Cell Connection Torque Values," on maintenance form, and TORQUE:

nonconforming connection to applicable torque value.

2) - Refer To Attachment 1, DUCTOR cable connection, and RECORD new resistance measurement in Table - 4 on maintenance form.

3) E battery is isolated, Refer Tb Attachment 1 and DUCI'OR intercell connections, and RECORD each resistance measurement in Table - 4, as " FINAL" on maintenance form.

i MP 755.3 Level of Use-

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4)c IE battery is not isolated, Refer Tb Attachment 1 and -

hy.

RECORD cach resistance measurement in ihble - 4 on maintenance form as follows:

DUCTOR and RECORD first ductor measurement.

REVERSE polarity of ductor.

DUCTOR and RECORD second ductor measurement.

AVERAGE the first and second measurements ano RECORD final ductor value.

5) IE t.ny resistance measurement is stillgreater than -

acceptance criteria, Refer 7b Sections 4.4 and 4.5, and CLEAN and DUCTOR reassembled cable connection (s).

6)- IE subsequent disassembly and cleaning of connection does not bring satisfactory resistance results, CONSULT FLS or Engineering for direction.

-- 4.4 Disassembly, Cleaning, and Inspection of Cell Connections NOTE The following steps may be performed on an individual battery cell or the entire battery as necessary. -

4.4.1 ENSURE Operations Department has tagged battery out of service and opened applicable circuit breakers and disconnect switches.

STOP WARNING STOP Approved face shields, go

. aprons, along with a long ggles, acid-resistant gloves, and acid-resistant sleeved shirt, must be worn while maintenance on batteries is being performed.

4.4.2

- DON protective clothing and equipment.

,i MP 755.3 Level of Use Rev.0 ST P THlNK ACT-REVIEW General 19 of 27

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.C A U TI O N To avoid applying torque to baucry terminal posts, two insulated wrenches must be used.

4.4.3 Using two insulated wrenches, LOOSEN bolts attaching intercell connectors to cell posts.

4,4.4 IE necessary, LOOSEN lugs attaching inter-tier or inter-rack cables to cell posts, connectors, or terminal plates.

4.4.5 REMOVE the following from cell posts as necessary:

Tbrminal plates Intercell connectors

. Connecting hardware O

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C A UTIO N Care must be used ivhen cleaning intercell connectors, cell posts, and

- terminal plates to prevent removing lead coating.

Steel wool, sandpaper, or emery cloth must not be used to clean contacting surfaces, as these will damage the lead plating.

Cleaning solvents must not be used, as these may enter the cell, react-with the electrolyte, and cause crazing of jars and covers.

4.4.6 Using demineralized watet or neutralizing solution and cloths, CLEAN acid deposits and corrosion from the following:

Cells jars and covers Battery rack Cell posts Intercell connectors 1

Inter-tier and inter-rack cables snd lugs Connecting hardware 4.4.7 IE neutralizing solution was used, WIPE components and surfaces with demineralized water.

4.4.8 Using clean, low-lint cloths, thoroughly DRY components and surfaces.

4.4.9 Using soft-bristle brush or fine-grit abrasive (Scotch Brite)

BURNISil the following:

Cell post contact surfaces Intercell connectors Terminal plates Connecting hardware 4.4.10 Visually INSPECT disassembled components and cell posts for p

physical damage and deterioration.

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rs 4.4.11 1E inspection results are not satisfactory, CONSULT FLS for

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V further direction.

4.5 ' Assembly of Cell Connections NOTE One recommended oxide inhibitor is NO-OX-ID grease, licating grease will aid in grease application. The recommended method is to use a-hot plate and heat grease to cream-like consistency (maintain approximately 160 F) and dip ends of intercell connectors in grease.

Apply grease to posts using soft-bristle brush.

-4.5.1 APPLY thin coating of approved oxide inhibiting grease to cell posts and connecting hardware.

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-C A U TI O N-1.

Cell connectors must be installed alternately positive to negative.

Positive-to-positive and negative-to-negative connections must never be made.

2.

Washers must not be installed between the intercell connector and the cell post.

4.5.2 IE intercell connections use flat washers, ENSURE the following:

a.

Refer Tb Figure - 2, and PLACE washer with rolled edce toward connector.

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Figure - 2. Washer Placement on Intercell Connection Rolled edge of washer I

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Cell post s

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tg Intercell connector r

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I b.

PLACE washer between bolt head and connector, and between nut and connector.

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INSTALL intercell connectors and hardware on terminal posts and tighten hardware finger tight, mb MP 755.3 Level of Use REVIEW Rev.0 SY P THINK ACT-General 23 of 27

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C AUTION Tb avoid applmust be used;ying torque to battery terminal posts, two insulated wrenches

. NOTE Tath bolt head and nut of stainless steel hardware must be torqued to the prescribed torque value. Tbrquing only one side will not provid e the dni ed tightness.

t 4.5.4 TORQUE all connecting hardware (terminal post hardware, inter-tier cables to cell posts, and inter-rack cables to cell posts) as follows:

a.

Using two insulated wrenches,TOROUE both bolt head and

- nut to the following values:

llattery Torque (in-lbs) l-Station 150 (150 to 157)

Gas lbrbine 100 (100 to 105)

Neutron Monitoring System 100 (100 to 105)-

b.

-WHEN 4 to 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> has elapsed, using two i.isulated' wrenches, TOROUE both bolt head and nut to the values shown above, t

I t

Level of Use Ni f

[

MP 755.3 general 75 tov 'thiF ' I4CF ' ' REVIEW Rev.O pak.

['%.

6#4 A/%

24 of 27 1

g,.

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- 5, j REVIEW AND SIGN-OFF Q)

~ 5.1 The review and sign -off for this procedure is located on the applicable maintenance form.

- 6.- BEFERENCES 6.1 IEEE Std 450-1995,'IEEE Recommended Practice for Maintenance, Tbsting, and Replacement of Large Lead Storage Batteries for Generating Stations and Substations" 6.2 IEEE Std 484-1975,"lEEE Recommended Practice for Installation and.

Design of Large Lead Storage Batteries for Generating Stations and Substations"-

6.3 GND," Stationary Battery Installation and Operating Instructions" 6.4 GNB," Flooded Battery Interconnection Kits For: M, N, H and PDO Cell

% pes" 6.5 EPRI," Power Plant Electrical Reverence Series, Volume 9, DC Distribution System"

7.

SUMMARY

OF CHANGES 7.1 Original issue.

7.2 Procedure supersedea C MP 755D," Battery Cell Connections Maintenance and Ductoring."

7.3 Added steps for reversing polarity at ductor and averaging two readings when ductoring battery that is not isolated.

7.4 Added step to torque battery connections a second time when 4 to 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> has elapsed.

Level of Use MP 755.3

.STOP TMNK ACT REVIEW Rev.O ggggg.

25 of 27

t O, V, I

c

<s, c.

Att:cl'unent 1 Intercell Connection (Post-to-Post Measurement)

/'3 (shect i or !)

V I

I I

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DLRO 4

Evo-Post Cell l

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RA R,n DLRO Four-Post Cell I

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i DLRO o(j Six-Post Cell MP 755.3 Level of Use STOP THINK ACT REVIEW Rev.0 OOO8ral 26 of 27 h

s.

a. n t nes.b>

Attiefunent 2 Cable Connecilons (Lug-to-Post Measurement)

(Sheet 1 of 1)

DI.RO e

RAl C[

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P051 single post using terminal plates 1

' Cell x

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Multiple cables on g

If two posts using Battely Cell terminal plates W

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Multiple <% ies on single post g

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3 Multiple cables on multiple posts using terminal plates - Requires two lug-to-post measurements for each connection.

A 4

U Level of Use MP 755.3 ST P THINK '

_ACT REVIEW Rev.0 General 27 of 27

.______m_____-_

ma i_

k k _)) 1

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ic 9

• i M V III Q,-JA~/

_ I 41 13l Approval

() ApprovalDate Effective Date PORC Mtg. No.

llattery Connections Ductor Reatlings llattery ID AWO No.

Table - 1. Location and Resistanc.e of Cable Connections Station Battery 18A Station Battery 18B Connection Acceptance Connection Acceptance Position Criteria Position Criteria Connec lon Connec lon (Cell No.)

(pO)

(Cell No.)

( 0) 1 Terminal 65 1

Terminal 65 7 to 8 Inter-rack 65 19 to 20 Inter-rack 65 14 to 15 Inter-tier 65 30 to 31 Inter-tier 65 21 to 22 Inter-rack 65 41 to 42 Inter-rack 65 28 to 29 -

Inter-rack 65 60 Terminal 65 36 to 37 Inter-tier 65 44 to 45 Inter-rack 65 52 to 53 Inter-tier 65 60 Terminal 65

(

Neutron Monitoring Battery Connection Acceptance Position Criteria Connec lon (Cell No.)

(pO) 1 Terminal 65 12 Terminal 65 Table - 2.

Battery Cell Connection Torque Values Battery Torque Value (in-Ibs)

Station Batteries 18A & 18B 150 (150 to 157) g Gas Turbine Battery

- 100 (100 to 105) 4 U

Neutron Monitoring 1-A,2-A,1-B & 2-B -

100 (100 to 105) jia nt Form 755.3-1 j

age 1 of 6

llattery Conn'ectlois Ductor Readings Table - 3. Intercell Connection Resistance Measurements (Step 4.2.3.a.)

Re-Ductor Intercell Accop.

Ro Intercoli Ra

gcccp, Conne -

tance RA (pO)

RA Ra Connec-tance RA (pO)

RA Ra tion Criteria (pO)

DNA (pO)

(p0) tion criteria (90)

ONA (p0)

(pO) '

1 to 2 31 to 32 2 to 3 321033 3 to 4 331034 4 t0 5 341035 5 t0 6 35 to 36 6107 36 to 37 7 to 8 37 to 38 8 t0 9 381039 9 to 10 39to40 1010 11 4010 41 111012 4110 42 12 to 13 421043 13 to 14 9d to 44 14 to 15 44t045 15 to 16 45to46 16 to 17' 46 to 47 17 to 18 47to48 18 to 19 48to49 19t020 49 to S0 20 to 21 5010 51 21 to 22 51 to 52 22 to 23 5210 53 23 to 24 53 to S4 24to25 5410 55 25 to 26 55t056 26 to 27 56 t0 57 27 to 28 57 to S8 281029 58t0 59 29 to 30 59t060 30 to 31 Totals

. Total of allintercell resistance measurements..

p0 Number of measurements recorded........

O NA for Normal 3

- Average intercell resistance.................

p0

- Maintenance intercell Connection Resistance Acceptance Criteria p0 s

gia{nt,. Form 755.3-1 Page 2 of 6

llattery Conn. tion. Ductor Reatlings ec s

Table - 4. Cable Connections Resistance Measurements (Step 4.2.4.c.)

Cell (Post) Used Ductor Re-Cell (Post) Used Ductor Re-Type of for Lug-to-Post Value Ductor for Lug-to-Post Value Ductor Connection Reading (pO)

(pO)

Reading (pO)

(pO)

Station Batteries 18A and 18B Terminal Connection 1

60 7/19 7/19 (left post)

(right post)

Inter-rack Connection (Cells 7 to 8 for 18A)

(19 to 20 for 188))

8/20 8/20 (left post)

(right post) 14/30 14/30 (left post)

(right post)

Inter-tier Connection (Cells 14 to151or 18A)

(30 to 31 for 180) 15/31 15/31 (left post)

(right post) 21/41 21/41 Inter-rack Connection (Cells 21 to 22 for 18A)

(41 to 42 fer 18B) 22/42 22/42 (left post)

(right post)

O gia nt. Form 755.3-1 l' age 3 of 6 m

nu ar, a y y

linttery Conn'ectioifs lhictor 1(emlings Tablo - 4. Cable Connections Resistanco Measuromonts (Stop 4.2.4.c.)

Gell (Post) Used Ductor Ro-Cell (Post) Used Ductor Ro-Type of for Lug-to-Post Valuo Ductor for Lug-to-Post Value Ductor Connection Reading (pO)

(pO)

Reading (pO)

(pO)

Station Battories 10A and 100 (Cont'd) 28 28 (left post)

(right post)

Inter-rack Connection (18A only) 29 29 (left post)

(fight post) 30 36 (left post)

(right post)

Inter-tier Connection (18A only) 37 37

~~

(left post)

(right post) 44 44 (left post)

(right post)

Inter -rack Connection (18A Jnly) 45 45 (left post)

(right post)

O Maint. Form 755.3-1 Rev.O Eage 4 of_()

t.e %gyy;

't

~

7 n.s

....e llattery Connections Ductor Remlings Tablo - 4. Cablo Connections Resistanco Measuromonts (Stop 4.2.4.c.)

O Cell (Post) Used Ductor Ro-Cell (Post) Used Ductor Re-Type of for Lug-to-Post Valuo Ductor for Lug-to-Post Value Ductor Connocuon Roading (pO)

(pO)

Reading (pO)

(pO)

Station Battorios 18A and 180 (Cont'd)

Y 52 52 (left post)

(nght post)

Inter-tier Connection (18A only) i 53 53 (left post)

(right post)

I i

i Gas Turbine Battery Terminal Connection 1

50 14 14 Inter-tier (left post)

(right post)

Connection 15 15 (left post)

(right post) 28 28 Inter-rack (left post)

(right post)

Connection 29 29 (left post)

(right post)

Neutron Monitoring Battery Terminal Connection 1

12 Total of all cable resistance measurements,

p0 Number of measurements recorded........

O NA for Normal Average cable connection resistance......

p0 Maintenance Cable connection resistance acceptance criteria p0 for Type _

Total of all cable resc.ance measurements....

p0 Number of measurements recorded....... +

O NA for Normal Average cable connection resistance.........

pa Maintenance Cable connection resistance acceptance criteria p0 for Type Maint. Form 755.3-1 (ev. 0

' age 10f 6

.e r Itattery Connections 1)uctor Mendings Total of all cable resistance measurements....

p0

-1 Number of measurements recorded........ +

" O NA for Normal Average cable connection resistance.......,.

-p0 Maintenance

- Cable connection resistance acceptance criteria p0 for Type COMMENTS Job Supervisor Date O

O Maint. Form 755.3 lev. 0

' age 6 of 6

' $ T ')'[Y]

8,1(o L0 l' G'). l t

'Approvalk.J Approval Date Effectivo Date PORC Mtg. No.

(

llattery Connections Ductor Readings - Gas 'nirbine llattery (For Normal Maintenance Ductoring) llattery ID AWO No.

Table - 1. Location and Resistance of Cable Connections Gas Turbine Battery Conn Type of Acceptance 9

n Connection Criteria (Cell No.)

1 Terminal 14 to 15 Inter-tier T

28 to 29 Inter-rack Ta e - 4 42 to 43 Inter-tier 56 Terminal O

V Table - 2.

Battery Cell Connection Torque Values Battery Torque Value (in-lbs)

Gas Turbine Battery 100 (100 to 105)

COMMENTS Maint. Form 755.3-2 tev. 0

'agelof 3

i

~

Hattery Connections Ducto deadings - Gas 'thihine llattery I

Table - 3. Intercell Connection Resistance Measurements (Step 4.3.3.a.)

Accept.

Accept.

Criterla Re-Ductor Cr#erla Re-Ductor Intercell Intercoll l

Connec.

O'Ul*

')

RA Connec.

RA tion RA (pO)

RA tion RA (pO)

RA 1 to 2 54 291030 49 2to3 49 30 to 31 56 l

3 to 4 49 31 1o 32 58 4

]

4 to 5 52 32 to 33 53 5 to 6 56 33 to 34 50 6 to 7 60 34 to 35 47

-7 to 8 49 35 to 36 56 8 to 9

-47 30 t0 37 49 9 to 10 48 37 to 38 50 l

10 to 11 55 38 to 39 52 4

11 to 12 52 39 to 40 53 12 to 13 48 40 to 41 60 4

13 to 14 49 41 to 42 52 O

15 to 16 48 43 to 44 54 16 to 17 56 44 to 45 52 17 to 18 49 45t046 58 18 to 19 44 46t047 52 19 to 20 55 47 to 48 61 20 to 21 52 48 to 49 50 21 to 22 48 49 to 50 55 221o23 54 50 to S1 48 l

23 to 24 48 51 to 52 52 24 to 25

-48 52 to 53 49 l

25 to 26 50 53 to 54 60 l

26 to 27 44 54 to 55 53 27 to 28 47 55 to 56 56 TOTALS

• Accept. Criteria represents the benchmark (installation) connection resistance plus a 20% tolerance.

1 Maint. Form 755.3-2 lev. 0

' age 2 of 3

' /

-.......,, _ _,. _ _ _ _... _. _ _ ~ ~... _ _..

s 1

liaitery Connections Ductor Readings - Gas 'thrhine llattery 3

Table - 4. Cable Connections Resistance Measurements GT Battery (Step 4.3.4.a.)

Ductor Re-Cell / Post Used for Type of Connection Value Ductor Lug-to-Post Reading (90)

(nR) 1 Terminal Connection 56 Acc. Criteria 17 iso 14 Inter-tier Connection 15 Acc. Criteria 181:0 28 Inter-rack Connection 29 Acc. Criteria 25 sta 42 Inter-tier Connection 43 Acc. Criteria 191:0

• Acc. Criteria throughout table represents the benchmark (installation) cable resistances measured lug to l each post for specified cable, plus a 20% tolerance.

Job Supervisor _

Date i

Ab Maint. Form 755.3-2 lev. 0

' age 3 of 3

_____