Best Practice

SABP-P-002
Selection and Design of
Battery Monitoring System
Document Responsibility: CSD/ESD/Power Systems Unit

5 June 2006

Saudi Aramco DeskTop Standards

Table of Contents

1
2
3
4
5
6
7
8

Introduction..................................................... 2
References..................... 2
Definitions................................. 3
Safety Precautions .... 4
Types of Batteries... 6
Benefits of the Battery Monitoring System. 6
Battery Monitoring System Details.. 6
Battery Monitoring System Measured
Parameters. 10

Attachment # 1 General System Diagram....... 15

Previous Issue: New Next Planned Update: 5 June 2011
Page 1 of 15
Primary contact: Faisal A. Al-Dubaikel on 873-6466

Document Responsibility: CSD/ESD/Power Systems Unit

Issue Date: 5 June 2006
Next Update: 5 June 2011

SABP-P-002
Selection and Design of
Battery Monitoring System

Introduction
1.1

Purpose
The purpose of this document is to introduce parameters & information that are
usually provided by the battery monitoring system which will be useful for
battery maintenance and replacement purposes. It will also establish guidelines
for best battery monitoring system specifications and design.

1.2

Scope
This best practice is intended to give general guidelines of the meaning of
information & alarms obtained from the battery monitoring system and the best
actions to be taken in case any alarm is generated. It is also intended to help in
selecting and designing battery monitoring system.

1.3

Disclaimer
This best practice is provided for the general guidance and benefit of Saudi
Aramco engineers who would like to utilize BMS in their facilities. The use of
the information or material contained here will not release operating facilities
from their battery maintenance responsibilities.

1.4

Conflict with Mandatory Standards

In the event of a conflict between this Best Practice and other Mandatory Saudi
Aramco Engineering Requirements, the Mandatory Saudi Aramco Engineering
Standards shall govern.

References
This best practice is based on the latest edition of the references below, unless otherwise
noted.
2.1

Saudi Aramco References

Saudi Aramco Engineering Procedure
SAEP-350

Regular Maintenance and Testing for Industrial

Stationary Batteries

Saudi Aramco Engineering Standards

SAES-P-103

UPS & DC Systems

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SABP-P-002
Selection and Design of
Battery Monitoring System

Saudi Aramco Material System Specifications

2.2

17-SAMSS-511

Stationary Storage Batteries

17-SAMSS-514

Battery Charger/Rectifier

17-SAMSS-516

Uninterruptible Power Supply System

Industry Codes and Standards

Institute of Electrical and Electronics Engineers, Inc.

IEEE 1491

IEEE Guide for Selection and Use of Battery

Monitoring Equipment in Stationary
Applications

IEEE 450

IEEE Recommended Practice for Maintenance,

Testing, and Replacement of Vented Lead-Acid
Batteries for Stationary Applications

IEEE 1188

IEEE Recommended Practice for Maintenance,

Testing, and Replacement of Valve-Regulated
Lead-Acid (VRLA) Batteries for Stationary
Applications

IEEE 1106

IEEE Recommended Practice for Installation,

Maintenance, Testing, and Replacement of
Vented Nickel-Cadmium Batteries for
Stationary Applications

IEC 62060

Secondary Cells and batteries- Monitoring of

Lead Acid Stationary Batteries - User Guide

Definitions
AH capacity: The capacity assigned to a cell by its manufacturer for a given discharge
time, at a specified electrolyte temperature and specific gravity.
Battery Bank: One battery string or more than one string connected in parallel to form
a battery bank.
Battery Monitoring System: An unmanned fixed surveillance system for stationary
Battery application.
Battery String: Two or more cells connected in series to form a battery string.
End of discharge voltage: The cell voltage at which the discharge is terminated.
Normally, 1.75 VPC for lead acid and 1.10 for Ni-Cad.

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SABP-P-002
Selection and Design of
Battery Monitoring System

Equalize charge: Charging the cell at elevated voltage to correct inequalities among
battery cells.
Float charge: Charging the cell at low voltage barely higher than the battery terminal
voltage to keep the cell fully charged and compensate for self-discharge losses.
Internal Cell Impedance: Any ohmic value of resistance, conductance or impedance
which is based on the relation between the voltage and the current in a stationary battery
which is used as an indicator of a battery's state of health.
Load test: The discharge of a battery at a constant current or power to a specified end
of discharge voltage.
Nominal voltage: An approximated average cell voltage computed in the basis of 2.0
VPC for lead-acid and 1.2 VPC for Ni-Cad.
Sulfation: a condition that happens in low state of charge in which lead crystals that
are formed during discharge can become so large that they resist being dissolved during
the recharge process.
Specific gravity: The ratio of the density of electrolyte to the density of water at
specific temp. (e.g., 25C).
State of charge: The actual capacity of a cell, expressed as a percent of its rated
capacity, that would be available if discharge were to occur.
Thermal Runaway: A condition that is caused by a battery charging current that
produces more internal heat than the battery can dissipate. This condition takes place in
VRLA batteries and ultimately cases cell venting and permanent failure.
Vented cell: A cell in which the products of electrolysis and evaporation are allowed to
escape to the atmosphere as they are generated. These batteries are commonly referred
to as flooded.
VRLA: a cell that is sealed with the exception of a valve that opens to the atmosphere
when the internal gas pressure in the cell exceeds atmospheric pressure by a preselected amount. VRLA cells provide a means for recombination of internally
generated oxygen and the suppression of hydrogen gas evolution to limit water
consumption.
4

Safety Precautions
4.1

The following personal protective equipment shall be available in the battery

room before working with the batteries:
a)

Safety face shields and goggles

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4.2

SABP-P-002
Selection and Design of
Battery Monitoring System

b)

Safety aprons

c)

Acid resistance rubber gloves

d)

Eye washing facility (in case of acid contact with your eyes or skin, flush
your with water for continuous 15 minutes and contact a physician
immediately)

e)

Safety shoes

f)

Dry chemical fire extinguisher

g)

Thermometer

h)

Ample amount of neutralizing agent to neutralize electrolyte spillage

Lead acid battery: Bicarbonate of soda, mixed 0.1 kg to 1.0 liter water

Ni-Cd battery: Boric acid solution, mixed 50 gram to 1.0 liter water

Or other suitable neutralizing agent recommended by the manufacturer

for acid electrolyte spillage or the manufacturer of alkaline electrolyte
spillage, whichever applicable.

Use the following precautions when working on the batteries

a)

Use adequately insulated tools.

b)

Use caution when working on batteries since they represent electric shock
hazard.

c)

Prohibit smoking and open flames, and avoid the chance of arcing in the
immediate vicinity of the battery.

d)

Ensure the battery room ventilation is operational and the battery room
temperature is maintained at 25C.

e)

Ensure unobstructed egress from the battery room area.

f)

Avoid wearing metallic object such as jewelry.

g)

Ensure that all connections to load test equipment include short-circuit

protection.

h)

Neutralize static buildup just before working on a battery by having

personnel contact nearest effectively grounded surface.

i)

Make sure that all vents of the cells/batteries are closed tightly before
starting any battery testing process.

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Document Responsibility: CSD/ESD/Power Systems Unit

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SABP-P-002
Selection and Design of
Battery Monitoring System

Types of Batteries
There are basically three types of batteries that are used by Saudi Aramco:

Vented Lead Acid Battery

Valve Regulated Lead Acid Batteries (VRLA)

Vented Nickel-Cadmium Batteries

Benefits of the Battery Monitoring System

The battery monitoring system can perform many functions as listed in paragraph 7.2.1
on an automatic unattended basis. The advantage of battery monitoring system is its
ability to continuously monitor, collect, store, report and analyze data. The parameters
that are measured by the BMS vary from one manufacture to another.
Batteries are one of the most critical equipment which are needed to provide power to
critical facilities in case of power outage. The BMS can immediately identify any
battery problem and initiate instantaneous alarms which will guarantee that batteries are
always in good health when needed.

Battery Monitoring System Details

The intend of this section is to give the user an idea of the best system specifications.
This section is intended to give a general understanding and is not mandatory
specifications.
7.1

General System Design

There are different designs for battery monitoring system depending on the
manufacturer. Attachment # 1 shows typical battery monitoring system design.
The battery monitoring system should preferably have:
a)

Battery Monitoring Cabinet suitable for installation at the battery room.

b)

This cabinet should have local display where information can be obtained
locally and should have local programming keypad.

c)

This cabinet should contain the processor and wiring connections for all
battery voltage sense leads, current sensors, battery and ambient
temperature sensors and alarm output connection.

d)

This cabinet should have RS 232 serial port for connecting a local laptop
PC and also USB port. The laptop PC may be connected temporarily to the
BMS unit on battery site for programming, calibration and viewing
purposes.

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7.2

SABP-P-002
Selection and Design of
Battery Monitoring System

e)

Ability to transfer data to a central control room. Preferred communication

method is Ethernet connection. Other communication method such as, RS
485 connection, short-haul modem or telephone modem can be considered
upon availability and need. All required converters and switches that are
required to transfer data should be provided.

f)

BMS Software which is installed at the central control room computer.

g)

All required wiring, leads, connectors and sensors for measuring the
voltage, current and temperature.

Battery Monitoring Systems Capabilities

7.2.1

The typical data that should be monitored, displayed and recorded by the
battery monitoring system are:

Overall Battery bank and/or string voltage

Individual cell voltages

Battery float, charge, discharge and equalize current

Pilot cell temperature & ambient temperature

Individual cell impedance including inter-cell connection resistance.

All of these parameters should be continuously monitored during normal

operations and during all battery discharges.
7.2.2

The BMS should record all battery parameters specified above at the
remote central computer, at user-defined intervals.

7.2.3

The system should automatically display, store, and provide a printout of

all alarm conditions that is outside the user defined pre-set limits, as and
when they occur, at the Remote Central Computer.

7.2.4

The system should provide and maintain a complete log of all discharge
events, and an on-line display of battery voltage, individual cell voltages,
battery string current, average ambient temperature, percent capacity
discharged, and total current discharged in ampere-hours whenever the
battery is in a discharge mode. In addition to the numerical display, it
should provide a graphical display of the battery voltage and cell
voltages versus time.

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7.3

SABP-P-002
Selection and Design of
Battery Monitoring System

7.2.5

The system should store historical records of the internal cell impedance
and inter-cell connection resistance of each cell. Compare the values to
the baseline data for the specified type of cell. It should automatically
provide trend warning when a cell starts to deviate from acceptable
limits.

7.2.6

The battery monitoring systems should preferably provide alarms in the

plant DCS system to immediately acknowledge all alarms.

Battery Monitoring System Specifications

The following table addresses the preferred battery monitoring system
specification:
Input Power

120 Volts AC, 1 phase, 60 Hz

Operating Temperature Range

0 - 50C

Altitude

0 - 5000 feet above sea level

Humidity

10 95 % non-condensing

Enclosure

Depending on installation and should be

design according to NEMA 250 or IEC
60529
+/- 2 Degrees C

Temp. Measurement Accuracy

Overall Battery Bank Voltage
Individual cell voltage
Current Measurement Accuracy
Cell Impedance Measurement Accuracy

7.4

+/- 0.1 V
+/- .01V
+/- 1.0 % full scale
+/- 10

System Software
The system should be provided with up-to-date Windows based battery
management software for interface between the BMS and the local or the remote
computer. The software should manage all functions of the BMS and should
provide analysis and trending of the battery data. The software should be able to
auto-poll multiple monitoring systems on a programmed schedule. They system

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SABP-P-002
Selection and Design of
Battery Monitoring System

should be password protected against any programming changes. The software

should have different access privilege such as administrator, visitor, etc.
7.5

System Reporting
The system should have the following reporting capabilities:

7.6

Alarm condition instantaneous reporting. This automatic reporting by

exception should be displayed at the monitor connected to the remote central
computer and automatically dumped to a line printer connected to the remote
central computer.

Individual cell voltages over time (Data & Graph), graph should show
optimum voltage line, maximum and minimum allowable limits.

Individual cell impedance values over time (Data & Graph), the graph
should show the maximum and minimum allowable limits.

Total battery voltage over time (Data & Graph), graph should show optimum
voltage line, maximum and minimum allowable limits.

Battery & Room temperature over time (Data & Graph), this graph should
also display the optimum temperature line.

Discharge report Total battery voltage decay vs. time (Data & Graph).

Discharge report Cell voltage decay vs. time (Data & Graph).

Discharge report Cell dropout over time (Graph).

Discharge interval summary report.

Drawings
The vendor should supply the following drawings:

7.7

Dimensional outline drawings of enclosures, cable entrance location details,

and complete electrical wiring diagrams showing the interconnection of all
components of the system.

Installation drawings

Equipment nameplate data

Equipment specifications

Owner's Manual
Each system should be provided with three (3) sets of owners manual(s)
including the following information as a minimum:

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7.8

7.9

SABP-P-002
Selection and Design of
Battery Monitoring System

Installation & commissioning instructions

Operating instructions

Service instructions with calibration & trouble shooting guide

Spare parts list

Factory test report

Testing
7.8.1

Factory Acceptance Tests: The BMS should be factory tested to

demonstrate the functionality and performance required by this
specification. The test report should be included in the Owners Manual.

7.8.2

Site Acceptance Tests: Vendor should prepare site acceptance test

procedures, which should be used to validate the functionality and
performance required by this specification. Vendor should conduct the
site acceptance tests and document the results. The Vendor should
correct all deficiencies before final acceptance by the Buyer.

System Installation, Start-up, Commissioning & Training

The BMS vendor should provide a field start-up engineer to supervise the
system installation. After installation, the vendor field engineer should start up
the system and perform all required site acceptance tests to demonstrate that the
system meets the functionality and performance requirements of this
specification. The field start-up engineer should also provide on-site training to
the facility engineer and technicians.

Battery Monitoring System Measured Parameters

The following information is obtained from IEEE 1491 & IEC 62060 regarding usual
battery monitoring system obtained parameters, their description and corrective action.
The typical parameters are usually monitored by the battery monitoring system are
mentioned above in paragraph 7.2.1. IEEE 1491 indicates that battery monitoring
system can be provided with additional parameters that depend on the battery
monitoring system manufacturer such as:

AC ripple current/voltage

Specific Gravity

Electrolyte level

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8.1

SABP-P-002
Selection and Design of
Battery Monitoring System

Measured Parameters Indication

The following will talk about each measure parameter meaning, indication and
purpose of monitoring;
8.1.1

Float Voltage
This is the voltage that is applied to the battery cell in the normal state by
the battery charger in order to maintain its full charge condition. This
value should be continuously monitored in order to indicate an out of
range float voltage on any cell which will affect the battery life time.
The proper float voltage is usually set by the battery manufacturer.
Higher than normal float voltage for long time might result in
accelerated grid corrosion, excessive gassing and increased water
consumption, thermal runaway in VRLA batteries and premature end of
life. Lower than normal float voltage will result in battery capacity loss,
irreversible sulfation, accelerated grid corrosion and premature end of
life.

8.1.2

Equalization Voltage
Equalization voltage is a voltage level set by the battery manufacturer
which is higher than the normal float voltage. Equalization voltage is
usually applied in order to correct inequalities that happen in the voltage
or specific gravity between batteries in the battery bank.
Equalization voltage should be monitored in order to make sure that its
value and duration is as recommended by the battery manufacturer. If
equalization voltage is too high or too long, it will result in increased
battery temp, excessive gassing, water consumption, grid corrosion and
premature end of life. Low level equalization voltage might require
longer time and too short equalization voltage might not achieve the
desired results

8.1.3

Open Circuit Voltage

This is the voltage at the battery terminal in case all charging sources and
loads have been removed. This value is usually monitored in order to
indicate if the open circuit voltage is within the manufacturer acceptable
limits. The open circuit voltage can indicate cell state of charge or a
shorted cell if the value is too low.

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8.1.4

SABP-P-002
Selection and Design of
Battery Monitoring System

Battery Discharge Voltage

Battery voltage can be monitored during battery discharging state. This
value along with the discharge rate and time can be used to indicate
battery health and also to predict battery performance.

8.1.5

Battery DC current
Each individual cell current should be the same as the battery sting
current if there is no ground fault present. Battery monitoring system
can monitor the float current, discharge current, charge current and
equalization current. All these values can be monitored and compared to
the manufacturer data in order to indicate the state of health of a battery.
The float current depends on the temperature, float voltage and battery
condition. Big difference in the float current from the manufacturer
recommendation may indicate problem in the battery system or the
charging system. High level float current may indicate failing cells in
the battery bank, high charge voltage, ground fault, contaminated
electrolyte or high temperature. Absence of float current may indicate an
open circuit or charging system failure. A rising trend of float current
may indicate battery degradation and a start of thermal runaway in
VRLA batteries.
The magnitude of the discharge current compared with the battery
capacity can give an indication of the run time. Each battery
manufacturer should provide a table or chart of different discharge
current values and the expected run-time of the battery. Also with a
constant voltage, the charging current should come to a constant value
when the battery becomes charged.

8.1.6

Cell Impedance
Cell impedance is any ohmic value of resistance, conductance or
impedance which is based on the relation between the voltage and the
current in a stationary battery which is used as an indicator of a battery's
state of health.
Changes in the ohmic values in excess of a specified set value from the
battery manufacturer at the same temperature should be considered
significant and can indicate change in the battery health state. It is very
important to establish a baseline of the internal cell ohmic value for
future comparison. BMS can provide the trend of the cell internal
impedance whether it is decreasing or increasing over time which might
require close monitoring of the battery.
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SABP-P-002
Selection and Design of
Battery Monitoring System

In case there is a significant change in the cell internal impedance from

the manufacturer recommendation or the established base historical
value, more immediate testing such as a load test should be conducted in
order to indicate the battery state of health.
It should be noted that if cell ohmic value is still within allowable limit,
this does not guarantee that the battery is in a healthy state.
8.1.7

Interconnection Resistance
This is the resistance of the intercell connection measured between the
battery connected posts which include both the resistances of the
connection and the bolted connection.
The typical value of the cell interconnection resistance is from 10~100
depending on the size of the battery. Corrective action should be
taken if the value changes more than 20% from established baseline.

8.1.8

Battery Cell Temperature

It is common to measure one pilot cell temperature in a battery bank and
more measuring points are ok. Difference between ambient temperature
and battery temperature should be monitored and always kept below
manufacture recommendation. Increase in a battery cell temperature
than ambient temperature may indicate higher than normal charging
voltage, high ripple current or potential thermal runaway in VRLA
batteries.
Keeping a record of the battery operating & ambient temperature may be
used for warranty validation.

8.1.9

Ambient Temperature
The ambient temperature is one of the most critical parameters that
should be monitored. The ambient temperature affects both the battery
capacity and the battery lifetime. The battery lifetime is normally
specified at 20~25C. If the ambient temperature is increased by 10C,
the battery lifetime is expected to decrease by 50%.
High ambient temperature also affects the battery self discharge and the
battery float current. Both battery self discharge and float current
increase with increase temperature. Also, more water consumption is
expected with higher temperature.

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SABP-P-002
Selection and Design of
Battery Monitoring System

8.1.10 Ripple Voltage and Current

The ripple voltage and current is the AC component that is available in
the DC bus. It is usual to have higher AC ripple voltage and current in
UPS system batteries than in the DC system batteries since the load is
not sensitive to DC ripples in UPS applications.
Higher than normal voltage ripple may cause high water consumption in
vented batteries and thermal runaway in VRLA batteries. High ripple
voltage may indicate problem in the battery charger that need to be fixed.
Higher than normal ripple current may generate heat within the battery
which might increase the battery operating temperature.
8.1.11 Specific Gravity
Specific Gravity is the ratio of the density of electrolyte to the density of
water at specific temperature. During the discharge operation, acid is
consumed and water is produced. During the charge operation, water is
consumed and acid is produced. Because sulfuric acid is much denser
than water, specific gravity measurement may be used for checking the
state-of-charge of a battery.
8.1.12 Electrolyte Level
At all times, the level of the electrolyte should be between the minimum
and the maximum mark on the battery jar which is specified by the
battery manufacture. This is very important to prevent plates drying.
The rate of water consumption can give indication of an overcharging in
healthy new cell or the need to replace an old cell.

5 June 2006

Revision Summary
New Saudi Aramco Best Practice.

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SABP-P-002
Selection and Design of
Battery Monitoring System

Attachment # 1 General System Diagram

Battery Monitoring
System on-site cabinet

Cell
1

Measurements of Voltage, internal

impedance, current, tempsetc are
obtained at the local BMS cabinet

Communication
line, an example
is Ethernet
telephone line,
RS-232 or RS485

Cell
2

Cell
3

Cell
N

Remote BMS Computer at

Central Control Room where
BMS software is installed and
data is collected

Battery Bank

This is preferred option to

connect the system to Plant
DCS.

Plant DCS

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