HARYANA VIDYUT PRASARAN NIGAM LIMITED
TECHNICAL SPECIFICATION NO.SSD/S-01(R1)/DGM-751
FOR
220V (600AH / 200AH & 100AH) AND
48V (800AH / 300AH & 120AH) BATTERY BANKS
Chief Engineer, MM,
HVPNL, Panchkula
Telephone & Fax No.
:
0172- 2583724
AUGUST, 2013
0
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 charger and one (1) battery set for each of 220V and for 48V
system. DC scheme shall consists of one (1) battery.
2.0.3 Bidder shall select number of cells, float and Boost voltage to achieve following
requirement :
System
Voltage
220 Volt
48 Volt
2.1
Maximum Voltage
during Float
Operation
242 Volt
52.8 Volt
Minimum voltage available
when no charger working
and battery fully discharged
up to 1.85 V per cell.
198 Volt
43.2 Volt
Minimum
Nos of Cell
107
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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 C
Max. daily average ambient temperature
450 C
Max. yearly weighted ambient temperature
350 C
1
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
conditions prevail altitude above MSL
4 months (June to
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 Type
The DC Batteries shall be Normal Discharge type Valve Regulated Lead Acid
(VRLA) and shall conform to IS 15549: 2004/IEC 60896-21 & 22, 2004
standard. These shall be factory filled, charged & suitable for a long life under
continuous 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 the
manufacturer.
3.2 Constructional Requirement
Plates:
Positive plates shall be made of flat pasted type using high corrosion resistant
alloy for durability, maintenance free, long life both in cyclic as well as in float
applications. The Grids are of Semi Radial Squarish grid to reduce internal
Resistance and travel current in shorter time.
Negative plates shall be heavy duty, durable flat plate using lead alloy pasted
Semi Radial Squarish Grid. Negative plates shall be designed to match the life of
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 for
preparation 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 and
shall have chemical and electro-chemical compatibility along with acid resistant
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.
2
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 handle
the internal cell pressure of the cells in the worst working condition.
The container shall be capable of withstanding the rigours of transport, storage
and 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 container
material 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 shall
be such that the seepage of electrolyte, gas escapes and entry of electrostatic
spark 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 grade
Sulphuric acid along with good insulating properties. Sufficient separator overlap
and PVC shield protection to bottom edges of the plates is to be provided to
prevent 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 be
self re-sealable. The vent plug shall be made with suitable grade of fire retardant
plastic 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 and
hydrogen / 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 terminals
shall have adequate solid copper core cross-section to avoid overheating at
maximum current load. The surface of the terminal post extending above the cell
cover including bolt hole shall be coated with an acid resistant and corrosion
retarding 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 a
proven material that does not have any harmful effect on cell performance. Both
Positive and negative terminal posts of VRLA Battery shall be colored Red and
Black to make it unambiguously identifiable.
3.8. Connectors, Nuts & Bolts, Heat Shrinkable Sleeves
The connectors shall be non corroding lead coated copper of suitable size to
enable 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
acid resistant characteristics. All inter cell connectors shall be protected with heat
shrinkable silicon sleeves for reducing the environmental impact including a
corrosive environment.
3
3.9. Flame Arrestors
Each cell shall be equipped with a Flame Arrestor to defuse the Hydrogen gas
escaped during charge and discharge. Material of the flame arrestor shall not
affect 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 have protection
against fungus growth and other harmful effect due to tropical environment. The
suitable insulation shall be provided between stand/frame and floor to avoid the
grounding of the frame/stand. The joining of the frames should not 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 (rated
capacity, corrected at 27º 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 exhausted
condition (1.75V/cell) within 10 hrs up to 90% state of charge. All the cells in a
battery shall be designed for continuous float operation at the specified float
voltage throughout the life.
The capacity (corrected at 27ºCelcius) 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 charged
battery 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 35º Celsius
for a period of 6 months shall not be more than 60% and the cell/battery shall
achieve 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 throughout
the storage period. Ampere hour efficiency shall be better than 90% and watt
hour 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 27º 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 its
rated capacity.
The battery sets shall have a minimum expected life of 20 years at float
operation.
4
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/IEC
60896-21 & 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 standards
within last seven years. The Contractor/Supplier shall submit necessary
evidences enclosed along with tender documents.
Sr.No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Description
Gas Emission
High Current Tolerance
Short Circuit Current and DC internal resistance
Protection against internal ignition from external spark source
Protection against ground short propensity
Content & durability of required marking
Material Identification
Valve Operation
Flammability Rating of material
Intercell connector performance
Discharge Capacity
Charge Retention during storage
Float Service with daily discharge for reliable mains power
Recharge behavior
Service life at an operating temperature of 40 0 C for brief
duration exposure time
Impact of stress temperature of 60oC for brief duration
exposure time with 3 hours discharge test
Abusive Over discharge
Thermal runway sensitivity
Low temperature sensitivity
Dimensional sensitivity at elevated internal pressure &
temperature
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 test
2. Visual Inspection
3. Dimensions, Mass & Layout
4. Marking & Packing
3.14.2 Acceptance Test of Battery
1. Polarity Marking
2. Verification of Dimensions
3. Test of AH Capacity.
5
3.15. List of Factory & Site Tests for Battery
Sr.No
Test
Factory Tests
1
2
Physical Verification
C/10 Capacity test on the cell
Yes
Site Tests
Yes
3.16. Installation and Commissioning
Manufacturer of battery shall supervise the installation as recommended in O&M
manual/or relevant standards. All necessary instruments, materials, tools and
tackles required for installation, testing at site and commissioning are to
arranged 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)
b)
c)
d)
e)
f)
Nominal Voltage
Manufacturer’s name, type and trade name.
AH capacity at 10 hour rate.
Voltage for float operation at 20 deg. C with tolerance of (+/-) 1%.
Month & year of manufacturer
Country of origin.
S.No. of cell/cell No.
4.1.1
The cells and batteries may also be marked with the ISI certification mark, if
any.
4.2 PACKING:
The cells shall be suitably packed so as to avoid any loss or damage during
transit.
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 and
every battery set. The manufacturer shall supply 5 copies of instructions manual
to the purchaser.
The following information shall be provided on, the instruction cards.
a) Designation of cell or battery
b) Ampere hour capacity.
c) Nominal voltage
d) Manufacturer’s instructions for charging
e) Voltage for float operation at 20 deg.C with tolerance (+/-) 1%.
f) Maintenance instructions
g) Environmental & safety provisions required.
6.0 TESTS:
All the acceptance tests as per relevant standards mentioned shall be carried out
for 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 be
submitted for approval of purchaser.
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7.0 DRAWINGS:
The tenderer will submit the detailed dimensional drawings for battery sets
including 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 attached
shall 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
:
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