Substation battery swap time required

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paulengr

Senior Member
Have a question about time required to swap a "typical" 60-120 cell, 150 lb./cell substation battery. Haven't had to estimate these before.

NECA Manual of Labor Units gives an estimate of around 3.5-5.5 hours "each" for this work and includes unloading/staging, placement, connecting everything, and teardown/cleanup/disposal.

For a 120 cell string @ say 4 hours, that comes up to 480 man-hours or 6 man-weeks which frankly seems very, very excessive. But if I go the other way and figure that "each" means per battery and not per cell then we must be talking about an extremely small UPS battery such as the larger ones that come with a separate cabinet and not a utility substation battery because at say 4 hours or 240 minutes, that gives a total of just 4 minutes per cell to do everything for a 125 VDC typical switchgear battery (60 cells), which doesn't even seem like enough time to unload and stage the old ones and to place, strap, and load the old ones on a truck.
 

brian john

Senior Member
Location
Leesburg, VA
How many battery strings are you talking about?

We do battery work all the time

1. Disassemble old batter
2. PROPERLY palletize, cardboard under and over the cells, banded to the pallet.
3. clean racks
4. place new cells on racks
prepare post and intercell connectors per the manufactures instructions.
5. install intercell connectors and hardware.
6. Torque all connections per the manufactures instruction.
7. Micro-ohm readings.
8. Turn charger on, monitor voltage and current as you clean up.
9. Dispose of old batteries in an approved method.
10. return in 3-5 days to measure and record voltage and specific gravity readings

Submit report to owner

5 men ten hours to remove and reinstall.
Truck charge for hauling old battery for scrap.
4-6 hours to return to complete readings
 
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