STANDARD OPERATING PROCEDURES – (FOR CATEGORY “A” JOBS)

Form No. : EHSMSM/446/4013 Form Rev. No. : 01 Effective date: 01.01.2011

SOP No. MUEM/CRM/UTL/BTRY/01 Effective Date 25-07-2019 REVISION No 00

SOP DESC Lead Acid Battery / Battery Bank Replacement at Section
1LBDS1 ECR CRM Utility
DEPARTMENT Mills & Utility Electrical Maintenance Pages

Step Activity (WHAT) ASSOCIATED Responsibility Process / tools / PPEs (HOW) Remarks /
No. Requirements/Hazards/impacts (WHO) Reference
E-permit clearance will be taken before Learning from
starting the job from appropriate authorities. past incident.
Take proper SAFETY: Wrong Identification of equipment / Safety induction training will be given to all
clearance Electric shock / Flash. Sr. Associate / the workmen.
1. JE / Brief description about hazards/safety
Associate measures to be given to all workers.
First Aid box will be kept near to the site.
All workmen will use safety shoes, safety
helmets (with name, blood group, and working
agency name), safety goggles, hand gloves,
leg guard.
Constant supervision will be there at site.
Job will be carried out in presence of
competent safety supervisor.
At least two persons must be involved in the
job.

ENVIRONMENT: Hot, Noise,etc

QUALITY: Person/Persons who was/were

not part of the Job Planning/Discussion must
not participate in the job execution.

2. SAFETY: Electric Shock, Electrocution Sr. Associate / Check the healthiness of Battery Chargers.
Check healthiness ENVIRONMENT: :- NA JE / Incoming power to charger circuit should be
 STANDARD OPERATING PROCEDURES – (FOR CATEGORY “A” JOBS)
Form No. : EHSMSM/446/4013 Form Rev. No. : 01 Effective date: 01.01.2011

of both the battery QUALITY: :- Defective multi-meter may Associate ON and either MAIN or STANDBY charger
chargers misguide. should be in service.
For MAIN charger in service, check SW9
switch should be in PFSM position and SW3
and SW4 should be ON position.
For STANDBY charger in service, check
SW9 switch should be in PFSS position and
SW7 and SW8 should be ON position.
3. Check output load SAFETY: Electric Shock, Electrocution Check the output load current at the rear side of
current of both both the battery chargers.
battery chargers Check the battery load current.
and battery load. Sr. Associate / Battery load current should not be greater than
JE / 5A
ENVIRONMENT: NA Associate and
Crane
QUALITY: Defective multi-meter may Operator Use DC clamp meter.
misguide.
4. Disconnect the SAFETY: Electric Flash, if the battery is in Sr. Associate / Reduce DC load by putting OFF DC3 MCB at
Power operation. JE / individual breaker control panel.
ENVIRONMENT: NA Associate
QUALITY : NA Switch OFF SW3,SW4 , SW7 and SW8 MCB in
charger panel. Battery Charger to disconnect the
Environment: NA
Battery from Main stream.
Ensure the correct battery charger MCBs are put
OFF.
5. Entering Battery SAFETY: Tripping Hazard, Room may be Sr. Associate / Before entering battery room, ensure the light is
Room filled with hydrogen that may cause suffocation JE / ON, else put it ON.
& fire. Associate Ensure the exhaust fan is ON before entering. If
ENVIRONMENT: To ensure proper it is OFF then wait for some time (5 minutes)
illumination and fresh air in the room. after opening the door. Put it ON and ensure that
QUALITY: NA it is running during the job.
6. Isolate Battery SAFETY: Electric Shock, Electrocution, Sr. Associate / Battery load current should not be greater than
Bank electric flash may occur if both battery JE / 2A
terminals are shorted. Associate Disconnect Incoming terminals cable from
ENVIRONMENT: Spillage of acid from Battery Charger at battery bank end. Wrap cable
 STANDARD OPERATING PROCEDURES – (FOR CATEGORY “A” JOBS)
Form No. : EHSMSM/446/4013 Form Rev. No. : 01 Effective date: 01.01.2011

battery is undesirable, proper disposal of with electric tape.

defective battery. Isolate battery bank cells one by one and wrap
QUALITY: NA with electrical tape.
Do not touch or short both the terminals as
battery is charged.
Handle it carefully and do not tilt the battery
while handling.
Dispose the defective battery properly.

7. Prepare new SAFETY: Electric Shock, Electrocution, Sr. Associate / Connect all batteries in series with links provided.
Battery Bank electric flash may occur if both battery JE / Ensure the correct polarity of the cell.
terminals are shorted. Associate Check tightness of all links with proper size
ENVIRONMENT: Spillage of acid from spanner.
battery is undesirable, proper disposal of Remove the sealed vent plug (of new battery)
defective battery and use vent plug with hole.
QUALITY: NA Clean it by wearing hand gloves with the help of
dry or lightly wet cloth.
Apply Vaseline or petroleum jelly on the
terminals.
Do not tilt the battery while handling.

8. Connection to SAFETY: Electric Shock, Electrocution, Sr. Associate / Now Connect main cables from Battery Charger Use rubber gloves.
new battery bank electric flash may occur if both battery JE / Panel to 1st & last battery. Tighten the terminal
terminals are shorted. Associate with the help of proper size spanner.
ENVIRONMENT: Spillage of acid from
battery is undesirable, proper disposal of
defective battery
QUALITY: NA
9. Take the battery Safety: - Electric flash, shock Sr. Associate / Switch ON SW3,SW4 , SW7 and SW8 MCB in
in service. Environment:- Hot, Noise, Chemical etc JE / charger panel.
Quality:- Trained person to be involved. Associate Put ON DC3 MCB at individual breaker control
panel.

10 Check output load SAFETY: Electric Shock, Electrocution Sr. Associate / Check the output load current at the rear side of
current of both ENVIRONMENT: NA JE / both the battery chargers.
 STANDARD OPERATING PROCEDURES – (FOR CATEGORY “A” JOBS)
Form No. : EHSMSM/446/4013 Form Rev. No. : 01 Effective date: 01.01.2011

battery chargers QUALITY: Defective multi-meter may Associate Use DC clamp meter.
misguide. Ensure that the output load current of battery
chargers should be as per earlier configuration.
11 Disposal of old Safety: - Acid burn injury Sr. Associate / Dispose the Lead Acid Batteries as per Be careful to avoid
batteries. Environment:- Hot, Noise, Chemical etc JE / Common Procedures on Waste Management. any spillage or
splash of
Quality:- Trained person to be involved. Associate electrolyte during
handling battery.
Ensure lime dust is
available.

12 Return the SAFETY: N/A Sr. Associate / Cancel work permit clearance after job
working ENVIRONMENT: N/A JE / completion.
clearance QUALITY: N/A Associate

PREPARED BY APPROVED BY
Name and Jivan jyoti Jena / Jr.Engineer Name and SUMANTA CHAKRABORTY, (Sr. Manager)
Designation Designation
Signature with Date Signature with Date