SMI (Cell)

b) As per theoretical calculations of water loss in hard rubber container battery interval of water topping up should be between 4 to 5 months.

For PPCP battery it should be 6-7 months.

c) Initially battery should be topped up to green/ maximum mark on the float guide. During monthly inspections position of float should be watched.

Water should again be topped up when the float reaches red / minimum mark.

Time interval for float to reach red mark from green mark should be noted. Frequent topping up in between simply increases the maintenance workload.

d) If water consumption in a particular cell is more check the following:

i) Over heating of cell

ii) Any crack on lid or container.

iii) Leakage from vent plug or float guide

iv) Crack in sealing or pinholes.

v) If water consumption is more in all the cells, then charging voltage should be checked and adjusted as per 2 (a).

e) Frequency of topping up should be recorded by the depot. If interval between successive topping up of water in batteries is less than the interval

given in Clause (b) above, then matter should be reported to the manufacturer and RDSO, after satisfying that there is no other reason of excessive water loss

as explained in Clause (d).

5. AGENCY FOR IMPLEMENTATION:

All the TL/AC Depots of Railways.

6. PERIODICITY OF IMPLEMENTATION:

During normal maintenance of Coaches.

7. REFERENCE:

RDSO Specification No. ELPS/SPEC/TL/09

8. DISTRIBUTION:

As per enclosed list.

(H. Malhotra)

for Director General (PS & EMU)

Home

RDSO/PE/SMI/TL/0024-2004 (Rev. 1)

No. EL/6.7.50 Dated : 1/10/04

SPECIAL MAINTENANCE INSTRUCTIONS FOR VRLA BATTERIES FITTED ON TL AND AC COACHES

1. OBJECT:

Revised and simplified SMI 0024-2003 (Rev.0) was issued in super session of earlier SMIs TL/0020-2002 and TL/0023-2002 on 20.06.2003.

Revision 1 of this SMI is being issued with the change of constant current charging in place of constant voltage charging during POH schedule only.

2. MONITORING AT YARDS/DEPOTS:

(a) VOLTAGE SETTING OF ALTERNATOR

Ensure that the setting of the alternator cum regulator is as under:

Alternator voltage settings as mentioned above shall be done at half load i.e. 97A and 19A for AC and TL coaches respectively,

at 1500 rpm.

(b) CHECKS DURING TRIP INSPECTION

(i) Check for bye passing of failed cells. If bye-passed cells are found replace these failed cells immediately with the healthy ones.

(ii) Dust accumulation – if observed, clean with dry cotton cloth.

(iii) Cell cover / container cracked or burst – if noted replace the cell with a healthy cell immediately.

(iv) In case of battery terminal / cable over heating sign, check for loose connection at the cell terminal post / cable end. If required replace the cable immediately.

(v) Protective lid on safety valve – if missing provide new one immediately.

(vi) Check for arrival time of the Train. If train has arrived late due to heavy detention en-route due to some reasons, charge the coach battery bank as

per Annexure – 1 to bring up the State of Charge of the Battery Bank before putting the AC coaches again in Service.

(vii) Do not boost charge the cells for more than 12 hours.

3. QUARTERLY INSPECTION AT YARDS / DEPOTS :

(A) The following physical checks shall be made:

(i) Confirm the tightness of terminal bolt with torque wrench.

(Amararaja - 11 Nm, Exide – 22 Nm, HBL Nife – 10 Nm, Kirloskar – 12 Nm)

Do not overtighten.

(ii) Terminal post corrosion – if observed remove the cable and clean the terminal post and cable lug with brass brush or fine emery paper and apply petroleum jelly.

(B) Check open circuit voltage

(a) If the total battery bank open circuit voltage for AC and TL coaches is as under:

AC Coaches : 115.0 volts or above

TL Coaches : 112.0 volts or above

The following steps shall be followed:

(i) Discharge the battery bank with full coach load for 15 minutes

(ii) Note down the individual cell readings after15 minutes while the coach is still connected during the discharge.

(iii) If all the cell voltages are 1.98 Volts and above then the cells are in healthy condition – Charge the cells as per the Annexure and the same to be put in service.

(iv) If some of the cell voltages are less than 1.98 Volts then give boost charging with 2.30 VPC for 12 hrs. by charging them separately with current

limited to 20% of rated capacity

(v) The weak cells, which are charged separately must be checked through a discharge at C-10 rate for 30 minutes, the end of discharge voltage

should be above 2.0 V. If such a re-charged cell fails to qualify the above test, it should not be replaced back in the coach.

(vi) After performing the discharge test on revived cells, the cells need to be charged at least for 4 hours, prior to fitment in the coach.

(b) If the total battery bank open circuit voltage is as under for AC and TL coaches:

AC Coaches : Less than 115.0 volts

TL Coaches : Less than 112.0 volts

Charge the cells for 12hrs. with 2.30 VPC and then carry out the discharge test as per item No. 3 (a) above.

4. MAINTENANCE AT WORKSHOPS DURING POH:

The below given instructions are to be followed when the coach comes for periodic overhaul (POH) to the workshop.

(i) Remove all the cell terminal bolts, flat washers, spring washers, inter cell cables, connectors etc. (used insulated tools only)

(ii) Care should be taken to avoid any shorting of cell terminals while removing inter cell cable connectors.

(iii) Remove the stacking bolts used for fixing battery modules to battery box / cradle and between the trays.

(iv) Remove the modules with batteries from battery box / cradle by using suitable tool.

(v) Clean all the cell terminal posts and inter cell connectors / cable lugs with a brass wire brush to remove any sulphation layer.

(vi) Refix the inter cell connectors /cables and tighten the bolts along with flat and spring washers to specified torque. Replace old spring washers 100%.

Quality of new spring washers should be checked as per IS 3063 especially permanent set test.

(vii) Discharge the battery bank @ 0.1C and by pass each cell whenever it reaches end cell voltage of 1.75V.

(viii) Charge the cells at 7% constant current (77 Amps for 1100 Ah and 8.4 Amps for 120Ah) for 15 hours.

(ix) Again give rest to the cells for 6-8 hours.

(x) Discharge the cells at 12Amperes for 120 Ah and 110 Amperes for 1100 Ah gradually bypassing each cell whenever each cell

reach 1.75 V. Duration of discharge shall be recorded. If the discharge duration of the cells is found to be more than 8 hrs these

can be put back in service after charging.

(xi) If the cells do not give more than 8 hrs of discharge duration before reaching end cell voltage of 1.75 V, repeat this charging and

discharging cycle once more Cells should not be discharged below 1.75 V.

(xii) Even then, if the cells do not give more than 8 hrs. then the cells shall not be put in service.

(xiii) Clean and repaint the modules / cell trays. These may be numbered with the help of stenciling to identify the modules consisting of a battery set for a

coach (say Module No./ Set No.e.g.08/01 means 8^th module of Set. No.1). The other details like cell number, date of manufacture as indicated on the

cell lid and date of fitment shall also be recorded to monitor age-wise performance of the cells.

Note: All the new VRLA cells shall be given a boost charging if the cells have been lying in the Depot / Workshop for more than 6 month period from the

date of manufacture.

5. LOADING ON TO THE COACH :

(i) After recharge, remove all the inter cell connectors /cables etc., to avoid shorting of the cells during loading on to the battery box / cradle.

(ii) Petroleum jelly is applied over the inter cell connectors, wherever necessary.

(iii) Do not mix ordinary conventional / low maintenance cells with VRLA cells.

(iv) Put back the trays into the battery box / cradle as per the connection diagram and fix the stacking bolts between the steel tray to battery box / cradle and tray to tray.

(v) Do not mix the cells of different capacities and makes.

6. STORAGE OF CELLS:

The cells shall be stored only at the places, which are not exposed to direct sun light, rain, dust etc.

The stored area should be clean, dry and preferably indoor ambient temperature should be between 15 degrees to 35 degree.

Preferably the battery modules shall be stacked in not more than 5 tiers to avoid damage to the cell modules / cells at the bottom layer.

7. PERIODICITY:

Trip, Quarterly and Yearly (POH)

8. APPLICATION:

All types of self-generating TL & AC Coaches fitted with VRLA batteries.

9. AGENCY OF IMPLEMENTATION:

All the Zonal Railways / Production Units.

10. DISTRIBUTION:

As per enclosed list.(H. Malhotra)

for Director General (PS & EMU)

Home

RDSO/PE/SMI/AC/0032-2006 (Rev. O)

No. EL/ 6.7.19 Dated : 31-05-2006

SPECIAL MAINTENANCE INSTRUCTION FOR ( LMLA CELLS USED FOR RMPU AC COACHES.)

1. TITLE:

Monitoring and maintenance of 2V 1100 Ah LMLA cells

2. APPLICATION:

RMPU coaches fitted with LMLA cells

3. OBJECT:

Newly developed 2V1100Ah LMLA cells for A/C coaches are being used in Indian

Railways. These cells are of low maintenance feature and are designed to meet six

month topping up interval during service.

To ensure the topping up frequency of six month and satisfactory

performance, this SMI is issued.

4 . INSTRUCTION:

(a) Proper initial charging is of paramount important for battery performance. At the end of initial charging of 75 hours cell voltage shall not be less than 2.60 V in

three consecutive hourly reading and specific gravity shall be 1.240. If voltage is less than 2.60 V, the cell shall not be put into service and matter should be

reported to manufacturer. Also make sure that cells were charged at specified current and initial filling gravity as mentioned in the maintenance manual.

After 12 hours rest, discharge @ 110 amps constant current shall be taken. Battery should give more than 11 hours of discharge till end cell voltage of 1.8V is

reached. Finally charge the cells @ 110amps till three stabilised reading s are achieved.

(b) Ensure the voltage setting of Alternator /ERRU is as under for better performance and topping up frequency

130 Volt (shall be adjusted at 1500 rpm, half load)

(c) If Specific gravity of cells is less than 1.240 after train arrival, then Cells must be charged @ 110 Amperes for 2 –3 hours.

(d) To check the six-month topping up interval initially battery should be topped up to green/ maximum mark of the float guide. During monthly inspection position of

float guide shall be monitored. Water should again be topped up when the float reaches to red / minimum mark. Time interval for float to reach from green to red

mark should be noted. If it is less than six month the matter should be reported to RDSO and manufacturer.

(e) If water consumption observed in all or few cells is more (interval is less than six month) check the following.

1 Over heating of few cells

2 Crack in lid or container

3 Leakage from vent plug or float guide

4 Poor sealing of cells i e. between lid and container

5 If water consumption is more in all cells without any of the above, check and adjust the voltage setting as per Instruction(b).

(f) The cells should be charged every six-month with equalising charge rate as prescribed by manufacturer in the maintenance manual. This is required to bring

the lagging cells at par with other healthy cells.

(g) To check the state of charge of cell in battery box the full coach load shall be put on battery bank for 5 minute and the close circuit voltage shall be monitored it

should not be less than 108 V if cells are fully charged. At fan and light load only,the closed circuit voltage of cells shall be 112V. If voltage is found less then the

above the cells should be charged (as per ‘c’) till the voltage of each cell reaches 2.6V with charger connected.

(h) In every annual maintenance schedule (POH) the cells should be charged fully with correct electrolyte level and gravity. After 12 hours rest, discharge at

110Amp. up to the 1.8 V end cell voltage. Well maintained cells shall give more than 8 hour duration till 4 years of service.

5. AGENCY FOR IMPLEMENTATION:

All the TL/AC depots and workshop.

6. PERIODICITY OF IMPLEMENTATION:

On condition basis.

7. REFERENCE:

SMI TL / 0025.

8. DISTRIBUTION:

As per enclosed list.

(H. Malhotra)

For Director General (PS & EMU) Home

RDSO/PE/SMI/TL/0028 -2004 (Rev. O)

No. EL/6.7.2 Dated: 10 .0 6 .2004

SPECIAL MAINTENANCE INSTRUCTIONS FOR ( REVIVAL OF LEAD ACID BATTERIES )

1. TITLE:

Procedure of Revival of defective cells.

2. APPLICATION:

Flooded type Lead acid battery, which is used for TL / AC application.

3. OBJECT:

Failure analysis of TL/AC batteries shows that majority of failures of battery are on account of low voltage / low specific gravity of few cells in the set. If this is

not rectified timely then it leads to the dead cells or cell reversal. Many of the failed cells can be revived and put back into service. Therefore, this SMI is being

issued to guide the Railways for revival of those cells.

4. INSTRUCTIONS

(A) FOR LOW VOLTAGE AND LOW SPECIFIC GRAVITY

(a) In order to avoid this condition of cells, initial charging is of paramount importance. User must follow the instructions given by

supplier for initial filling with electrolyte and charging. Even after complete duration of charge, if any cell voltage is showing less

than 2.55 volts, such cells should not be put into service. Supplier to be informed to rectify the cells.

( b) During service if cell open circuit voltage is found less than 1.98 V. then discharge the cell at C10 rate till end cell voltage of 1.8 V

and then charge at C 10 rate.

(c ) In C10 rate discharge, if the cell does not give desired capacity, cycle shall be repeated once. (If cells are sulphated slow rate

charge i.e 50% of C10 rate is recommended to get the desired capacity)

(d) If gravity after charging is more than desired value adjust with D.M.water and charge for two hours for proper mixing

(e) If some cells are found lagging (1.98 – 2.00 V) then the cell requires boost charge at C10 rate for 2-3 hrs.

(f) If cells are stored for more than one month in fully charge condition then equalizing charge at 2.25V per cell or at the current

of 50% of C10 rate should be given for 5 to 6 hours every month.

(B) FOR DEAD CELL

This happens when plates are highly sulphated. It may be due to continuous undercharging or storing the cells in discharged condition.

(a) Pour out the electrolyte from the cell.

(b) Fill the cell with D.M. Water and allow 2 to 4 hour rest

(c) Charge the cell with 50% of C10 rate until voltage reaches to 2.3 to 2.4 V per cell. Voltage will not increase further due to weak

electrolyte.

(d) Dump the originally filled distilled water and fill with final gravity acid recommended at the end of full charge. Charge the battery

with normal charging rate until the voltage reaches to 2.6 to 2.7 V per cell.Check the gravity if it is less then final specified value

adjust with 1.400 specific gravity, if it is more adjust with D.M water and charge for two hour for proper mixing

(e) Conduct C10 discharge, if cell does not give desired capacity (serviced battery capacity shall be above 80%) Cell should not be

put in to service.

(C) CELL REVERSAL

This term is normally described as a reverse polarity and occurs when the battery is discharged deeply below the zero voltage and would not charge fully. If

deep discharge occurs no. of times without reaching fully charged condition battery shows reverse polarity. These batteries should be taken for revival action

immediately. Any delay shall reduce the possibility of revival. The following remedial action is recommended

a. Pour out the electrolyte from the cell.

b. Rinse the battery with D.M. water several times and dry.

c. Take action as given in ( B )– b, c, d, e.

d. If cells are not revived inform the manufacturer, who can take further remedial action.

5. AGENCY FOR IMPLEMENTATION:

All Workshops & Depots.

6. PERIODICITY:

On condition basis

7. REFERENCE:

Battery Maintenance Book / Catalogue

8. DISTRIBUTION:

As per enclosed list.

(H. Malhotra)

for Director General (PS & EMU) Home

RDSO/PE/SMI/TL/0029-2004 (Rev. O)

No. EL/6.7.8 Dated: 24.12.2004

SPECIAL MAINTENANCE INSTRUCTIONS FOR ( REVIVAL OF LEAD ACID BATTERIES )

1. TITLE:

Procedure of Revival of defective cells.

2. APPLICATION:

Flooded type Lead acid battery, which is used for Loco/EMU application.

3. OBJECT:

Failure analysis of Loco/EMU batteries shows that majority of failures of battery are on account of low voltage / low specific gravity of few cells in the set. If this

is not rectified timely then it leads to the dead cells or cell reversal. Many of the failed cells can be revived and put back into service. Therefore, this SMI is being

issued to guide the Railways for revival of those cells.

4. INSTRUCTIONS

(A) FOR LOW VOLTAGE AND LOW SPECIFIC GRAVITY

(a) In order to avoid this condition of cells, initial charging is of paramount importance. User must follow the instructions given by

supplier for initial filling with electrolyte and charging. Even after complete duration of initial charge, if any individual cell voltage is

showing less than 2.55 volts, (12.75 V per mono block) such cells should not be put into service. Supplier to be informed to rectify

the cells. During service, charging voltage setting should be 2.23- 2.25 volt per cell.

(b) If cell open circuit voltage is found less than 1.98 V or mono block voltage 9.9 volt then discharge the cell at C5 rate till end cell

voltage of 8.75 V and then charge at C 10 rate for 15 hrs. and conduct C5 discharge.

(c) In C 5 rate discharge, if the cell does not give desired capacity, cycle shall be repeated once. (If cells are sulphated slow rate

charge i.e 50% of C 10 rate is recommended to get the desired capacity)

(d) If gravity after charging is more than desired value adjust with D.M.water and charge for two hours for proper mixing

(e) If some individual cells are found lagging (1.98 – 2.00 V) then the cell requires boost charge at C 5 rate for 3-4 hrs.

(f) If cells are stored for more than one month in fully charge condition then equalizing charge at 2.25 V per cell or at the current

of 50% of C 5 rate should be given for 5 to 6 hours every month.

(B) FOR DEAD CELL

This happens when plates are highly sulphated. It may be due to continuous undercharging or storing the cells in discharged

condition.

(a) Pour out the electrolyte from the cell.

(b) Fill the cell with D.M. Water and allow 2 to 4 hour rest

(c) Charge the cell with 50% of C 5 rate until voltage reaches to 2.3 to 2.4 V per cell. Voltage will not increase further due to weak

electrolyte.

(d) Dump the originally filled distilled water and fill with final gravity acid recommended at the end of full charge. Charge the battery

with normal charging rate until the voltage reaches to 2.6 to 2.7 V per cell.Check the gravity if it is less then final specified value

adjust with 1.400 specific gravity, if it is more adjust with D.M water and charge for two hour for proper mixing

(e) Conduct C 5 discharge, if cell does not give desired capacity (serviced battery capacity shall be above 80%) Cell should not be

put in to service.

(C) CELL REVERSAL

This term is normally described as a reverse polarity and occurs when the battery is discharged deeply below the zero voltage and would not charge fully. If

deep discharge occurs no. of times without reaching fully charged condition battery shows reverse polarity. These batteries should be taken for revival action

immediately. Any delay shall reduce the possibility of revival. The following remedial action is recommended.

a. Pour out the electrolyte from the cell.

b. Rinse the battery with D.M. water several times and dry.

c. Take action as given in (B)– b, c, d, e.

d. If cells are not revived inform the manufacturer, who can take further remedial action.

Note: C10 rate = 10% current of rated capacity

C 5 rate = 20% current of rated capacity

5. AGENCY FOR IMPLEMENTATION: All Workshops & Sheds.

6. EQUIPMENT REQUIRED: (i) Full set Charger 0-150 V

(ii) Small charger 0-50 V 1 - 2 0 Amp (through selectorswitches)

7. PERIODICITY: On condition basis

8. DISTRIBUTION: As per enclosed list.

(H. Malhotra)

for Director General (PS & EMU) Home

RDSO/SMI/AC/17

No. EL/7.1.83/J-9 Dated 29.5.1998.

SPECIAL MAINTENANCE INSTRUCTION (Adjustment of voltage during pre-cooling)

1.0 TITLE :

Proper adjustment of voltage during pre-cooling of coaches through shore supplyto avoid over voltage to SMF Battery.

2.0 APPLICATION :

2.1 Selection of tapping available on pre-cooling transformer for proper charging of SMF batteries fitted on AC coaches with RMPUs during pre-cooling.

3.0 OBJECTIVES:

3.1 This SMI is issued to advise the Railways, the precautions to be exercised for proper charging and to avoid damage to SMF batteries due to over voltage

charging through pre-cooling transformer rectifier unit during pre-cooling. The output, as advised by SMF battery manufacturer, M/s Amara Raja, the output

voltage of transformer rectifier unit for charging SMF batteries having 54 cells and 56 cells should not be more than 124.2V and 128.5V respectively.

4.0 REFERENCE DRAWING : Nil

Instructions contained in this SMI have already been advised to Railways vide

RDSO’s letter No. EL/7.1.54/J9 dated 25/27.3.97.

5.0 INSTRUCTIONS:

5.1 Voltmeter and Ammeter which are already available in the pre-cooling transformer circuit on the coach.

6.0 PROCEDURE :

6.1 The tapping on the primary of transformer are connected to two 4 position rotary switches, one being for `coarse’ adjustment and other for `fine’ adjustment, in

such a way that the voltage indicated below are obtainable at the dc output for position 1-1 to 4-4 of the rotary switches.

· The intermediate d.c. output voltages, for various combinations of rotary switch

position shall increase from minimum to maximum in roughly equal steps when

the switches are operated from 1-1 to 4-4.

6.2 Maximum charging voltage of SMF battery having 54 cells and 56 cells should not be more than 124V and 128 V respectively, as the SMF batteries are voltage

sensitive. The output dc voltage of the rectifier unit during pre-cooling should be adjusted to as near to above and proper watch kept.

7.0 AGENCY FOR IMPLEMENTATION :

(1) AC staff during pre-cooling of AC coaches

(2) Workshop Staff during pre-cooling in POH.

8.0 DISTRIBUTION :

As per enclosed list.

Encl: Nil

Sd/-

(M.P. Singh)

Krite Maha Nideshak (EMU & PS) Home