111 battery specification

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HARYANA VIDYUT PRASARAN NIGAM LIMITED

TECHNICAL SPECIFICATION NO.SSD/S-01/DGM-751

FOR

220V (600AH / 200AH & 100AH) AND

48V (800AH / 300AH & 120AH) BATTERY BANKS

Chief Engineer, MM,

HVPNL, Panchkula


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TECHNICAL SPECIFICATION FOR

220V (600AH / 200AH & 100AH) AND

48V (800AH / 300AH & 120AH) BATTERY BANKS

1.0 SCOPE:

The scope of this specification covers design, manufacture, assembly, supply,testing at works, packing, forwarding, dispatch of VRLA batteries along with

necessary accessories, fittings etc. to the destination.

These equipments are to be complete in every respect, details to the functions

designated to the entire satisfaction of the purchaser. It is required that the

supplier accepting the contract agrees to furnish all apparatus, appliances and

material whether specifically mentioned or not but which may be found

necessary to complete, to perform and testing any of the herein specified

equipment (s) for compliance with the requirements implied without extra

charges. The erection/maintenance tools and specific tools if any will also form

part of supply.

2.0 General Technical Requirement

All the materials/components used in Battery Chargers and Valve Regulated

Lead Acid Battery (VRLA) shall be free from flaws and defects and shall

conform to relevant standards and good engineering practices:-

2.0.1 For 400 KV Sub-stations, DC System shall consist of two (2) battery sets for

each of 220V and 48V systems respectively.

2.0.2 For 220 KV, 132 KV & 66 KV sub-stations, DC System shall consist of two (2)float-cum-boost chargers and one (1) battery set for each of 220V system. For

48V system DC scheme shall consist of one (1) battery.

2.0.3 Bidder shall select number of cells, float and Boost voltage to achieve following

requirement :

System

Voltage

Maximum Voltage

during Float

Operation

Minimum voltage available

when no charger working

and battery fully discharged

up to 1.85 V per cell.

Minimum

Nos of Cell

220 Volt 242 Volt 198 Volt 107

48 Volt 52.8 Volt 43.2 Volt 23

2.1 CLIMATIC CONDITIONS:

The equipment to be supplied against the specification shall be suitable for

satisfactory continuous operation under the following tropical conditions:

Max. ambient air temperature 500

CMax. daily average ambient temperature 450 C


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Max. yearly weighted ambient temperature 350 C

Min. air temperature (-) 50 C

Max. humidity 100%

Min. relative humidity 26 %

Average number of thunder storm days per annum 40

Average annual rain fall 15 cm to 100 cm.

Number of months during which tropical monsoon 4 months (June to

conditions prevail altitude above MSL Sept). Varies from 61 meters

to 815.00 mtrs.

Average number of rainly days per annum. 120 days

Seismic level (Horizontal acceleration) 0.3g.

Degree of pollution Heavy

Intensity of solar radiation 1.0 KW/sq.m.

Max. Wind load 195 kg/sq.m.

3.0 Battery

3.1 TypeThe DC Batteries shall be Normal Discharge type Valve Regulated Lead Acid(VRLA) and shall conform to IS 15549: 2004/IEC 60896-21 & 22, 2004standard. These shall be factory filled, charged & suitable for a long life undercontinuous float operations and occasional discharges. The 220 V DC systems

should be unearthed and 48V DC system is Positive Earth system.

Battery sets shall be capable of operating at a peak ambient temperature of 50

Deg.C. The offered battery shall be compact and shall require no maintenance.

All safety equipment required for installation shall be provided by themanufacturer.

3.2 Constructional Requirement

Plates:Positive plates shall be made of flat pasted type using high corrosion resistantalloy for durability, maintenance free, long life both in cyclic as well as in floatapplications. The Grids are of Semi Radial Squarish grid to reduce internalResistance and travel current in shorter time.

Negative plates shall be heavy duty, durable flat plate using lead alloy pastedSemi Radial Squarish Grid. Negative plates shall be designed to match the lifeof positive plates and combination of positive and negative plates shall ensure

long life, durability and trouble free operation of battery.

Computer controlled/PLC operated in house equipment should be deployed forpreparation of lead oxide and paste to ensure consistency in paste quality &properties. Conventional / manual type of paste preparation will not be allowed.

3.3 Containers & Lids

The container & lids shall be made of polypropylene Copolymer material andshall have chemical and electro-chemical compatibility along with acid resistant


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and shall conform to UL-94/ ASTM-D-2863 standard. The material shall meet all

the requirements of VRLA batteries and be consistent with the life of battery.The porosity of the container shall be such as not to allow any gases to escape

except from the regulation valve.The tensile strength of the material of the container shall be such as to handlethe internal cell pressure of the cells in the worst working condition.The container shall be capable of withstanding the rigours of transport, storageand handling. The containers shall be enclosed in a steel tray.

For identification each cell / module shall be marked in a permanent manner to

Indicate the Following information.

I. Cell Serial number.

II. Positive and Negative is embossed on the cover

III. Month and Year of manufacturing.

3.4 Cell Covers

The cell covers shall be made of suitable material compatible with the containermaterial and permanently fixed with container by Hermetic Heat Sealing

technique. It shall be capable to withstand internal pressure without bulging or

cracking. Fixing of pressure regulation Valve & terminals posts in the cover shallbe such that the seepage of electrolyte, gas escapes and entry of electrostaticspark are prevented.

3.5. Separators

The separators used in manufacturing of battery cells shall be spun glass micro

porous Matrix having high acid absorption capability & resistant to battery gradeSulphuric acid along with good insulating properties. Sufficient separator overlap

and PVC shield protection to bottom edges of the plates is to be provided toprevent short circuit formation between the edges of adjacent plates.

3.6. Pressure Regulation Valve

Each cell shall be provided with a pressure regulation valve. The valve shall beself re-sealable. The vent plug shall be made with suitable grade of fire retardantplastic material. Each valve opening shall be covered with flame barrier capable in

preventing the ingress of flame into the cell interior when the valve opens andhydrogen / oxygen gas mixture is released. The valve unit shall be such that it

cannot be opened without a proper tool.

3.7. Terminal Posts

Both the Positive and Negative terminals of the cells shall be capable of proper

termination and shall ensure its consistency with the life of battery. The terminalsshall have adequate solid copper core cross-section to avoid overheating atmaximum current load. The surface of the terminal post extending above the cellcover including bolt hole shall be coated with an acid resistant and corrosionretarding material. Terminal posts or any other metal part which is in contact with

the electrolyte shall be made of the same alloy as that of the plates or of aproven material that does not have any harmful effect on cell performance. Both

Positive and negative terminal posts of VRLA Battery shall be colored Red andBlack to make it unambiguously identifiable.

3.8. Connectors, Nuts & Bolts, Heat Shrinkable SleevesThe connectors shall be non corroding lead coated copper of suitable size toenable connections of cells. Copper connections shall be suitably lead coated to

withstand corrosion due to Sulphuric acid/fumes.Nuts and bolts for connecting the cells shall be made of stainless steel with good


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acid resistant characteristics. All inter cell connectors shall be protected with heat

shrinkable silicon sleeves for reducing the environmental impact including acorrosive environment.

3.9. Flame Arrestors

Each cell shall be equipped with a Flame Arrestor to defuse the Hydrogen gasescaped during charge and discharge. Material of the flame arrestor shall notaffect the performance of the cell.

3.10. Battery Bank Stand

All batteries shall be mounted in a suitable metallic stand/frame. The frame shall

be powdered coated with acid resistant paint (2 coats) and should haveprotection against fungus growth and other harmful effect due to tropicalenvironment. The suitable insulation shall be provided between stand/frame andfloor to avoid the grounding of the frame/stand. The joining of the frames shouldnot leave crevices and ensure proper and tight fit.

3.11. Capacity Requirements

When the battery is discharged at 10 hour rate, it shall deliver 80% of C (ratedcapacity, corrected at 27 Celsius) before any of the cells in the battery

bank reaches 1.85V/cell.

The battery shall be capable of being recharged from the fully exhaustedcondition (1.75V/cell) within 10 hrs up to 90% state of charge. All the cells in abattery shall be designed for continuous float operation at the specified floatvoltage throughout the life.

The capacity (corrected at 27Celcius) shall also not be less than C and not more

than 120% of C before any cell in the battery bank reaches 1.75V/cell. The

battery voltage shall not be less than the following values, when a fully chargedbattery is put to discharge at C/10 rate:

(a) After Six minutes of discharge: 1.98V/cell(b) After Six hours of discharge: 1.92V/cell(c) After 8 hours of discharge: 1.85V/cell(d) After 10 hours of discharge: 1.75V/cell

Loss in capacity during storage at an average ambient temperature of 35 Celsius

for a period of 6 months shall not be more than 60% and the cell/battery shallachieve 85% of its rated capacity within 3 charge/discharge cycles and full rated

capacity within 5 cycles, after the storage period of 6 months. Voltage of each cell

in the battery set shall be within 0.05V of the average voltage throughoutthe storage period. Ampere hour efficiency shall be better than 90% and watthour efficiency shall be better than 80%.

3.12. Expected Battery Life

The battery shall be capable of giving 1200 or more charge/discharge cycles at

80% Depth of discharge (DOD) at an average temperature of 27 C.DOD (Depth of Discharge) is defined as the ratio of the quantity of

electricity (in Ampere-Hour) removed from a cell or battery on discharge to itsrated capacity.

The battery sets shall have a minimum expected life of 20 years at floatoperation.


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3.13. Accessories along with Battery System

Each battery shall be supplied with following accessories and devices:

a) Torque Wrench.b) Cell Test Voltmeter (-3-0-+ 3) Volts with least count of 0.01 Volt

3.14. Type Test of Battery

The contractor/Supplier shall supply type tested battery per IS 15549: 2004/IEC60896-21 & 22 over the range of at least one capacity per design and should

have met requirement of Service Life test as per above stated IEC standardswithin last seven years. The Contractor/Supplier shall submit necessary

evidences enclosed along with tender documents.

Sr.No Description

1 Gas Emission

2 High Current Tolerance

3 Short Circuit Current and DC internal resistance

4 Protection against internal ignition from external spark source

5 Protection against ground short propensity

6 Content & durability of required marking

7 Material Identification

8 Valve Operation

9 Flammability Rating of material

10 Intercell connector performance

11 Discharge Capacity

12 Charge Retention during storage

13 Float Service with daily discharge for reliable mains power

14 Recharge behavior

15 Service life at an operating temperature of 400 C for brief

duration exposure time16 Impact of stress temperature of 60oC for brief durationexposure time with 3 hours discharge test

17 Abusive Over discharge

18 Thermal runway sensitivity

19 Low temperature sensitivity

20 Dimensional sensitivity at elevated internal pressure &temperature

21 Stability against mechanical abuse of units during installation

Test shall be conducted in accordance with IEC 60896-21 & 22,2004 3.14.1 Routine Test of Battery

1. Physical examination test2. Visual Inspection3. Dimensions, Mass & Layout4. Marking & Packing

3.14.2 Acceptance Test of Battery1. Polarity Marking2. Verification of Dimensions

3. Test of AH Capacity.


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3.15. List of Factory & Site Tests for Battery

Sr.No Test Factory Tests Site Tests

1 Physical Verification Yes

2 C/10 Capacity test on the cell Yes

3.16. Installation and Commissioning

Manufacturer of battery shall supervise the installation as recommended in O&Mmanual/or relevant standards. All necessary instruments, materials, tools and

tackles required for installation, testing at site and commissioning are toarranged by battery manufacturer/Contractors.

4.0 MARKING AND PACKING:

4.1 MARKING:

The following information shall be indeligibly and durably marked on the outside

of the cell.

a) Nominal Voltageb) Manufacturers name, type and trade name.c) AH capacity at 10 hour rate.

Voltage for float operation at 20 deg. C with tolerance of (+/-) 1%.d) Month & year of manufacturere) Country of origin.f) S.No. of cell/cell No.

4.1.1 The cells and batteries may also be marked with the ISI certification mark, ifany.

4.2 PACKING:

The cells shall be suitably packed so as to avoid any loss or damage duringtransit.

5.0 INSTRUCTION MANUAL:The manufacturer shall supply one copy of instructions manual for initial charging(if required)/treatment, and routine maintenance during service, with each andevery battery set. The manufacturer shall supply 5 copies of instructions manualto the purchaser.

The following information shall be provided on, the instruction cards.

a) Designation of cell or batteryb) Ampere hour capacity.c) Nominal voltaged) Manufacturers instructions for charginge) Voltage for float operation at 20 deg.C with tolerance (+/-) 1%.f) Maintenance instructionsg) Environmental & safety provisions required.

6.0 TESTS:

All the acceptance tests as per relevant standards mentioned shall be carried outfor batteries in presence of our inspecting officer free of cost. Type test

certificates (not older than 7 years from the date of opening of tender) are to besubmitted for approval of purchaser.


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7.0 DRAWINGS:

The tenderer will submit the detailed dimensional drawings for battery setsincluding stands.

8.0 TYPE TEST CERTIFICATES:

The tenderer will submit the complete type test certificates as per relevant

standards mentioned (not older than 7 years from the date of opening of tender)for battery sets with their tenders, without which the offers are likely to be

ignored.

9.0 GUARANTEED TECHNICAL PARTICUALRS:

Guaranteed Technical Particualrs for battery sets as per Annexure-A attachedshall be furnished along with the tender.

10.0 ACCESSORIES:

Each battery set shall be supplied complete with all necessary accessories viz.stand, inter connections, cell no. Plates with sticker, multi meter complete with

leads, spanners.

11.0 BILL OF MATERIAL:

The firm shall also have to furnish the bill of material used in battery set.


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ANNEXURE-A

Guaranteed Technical Particulars

Battery Particulars

Battery Type :

Battery Rating :

Manufacturers Cell Designation :

No of Cells :

Cell Dimensions :

Single Cell Weight :

Battery Bank Dimensions :

Battery Bank Weight :

Product Details

Applicable Standards :

AH Efficiency :

WH Efficiency :

Self Discharge/Week :

Max. allowable Ambient Temp. at :

Which cell can safely operate

Recommended Max period of storage :

Material of container :

Type of Separator :

Material of Tray :

Method of Connection between cells :

Type of Connectors :

Cycle Life of Battery :

111 battery specification

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