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Technical Specifications for battery set

1. Scope of tender:

The scope includes design, manufacturing, testing at works, supply at site, installation, testing and
commissioning of 2 Volt, 100 Ah battery set for 110VDC supply for substations at RRCAT, Indore. The
details of the required batteries are as under.

Item No. Item Description Qty. Unit


1. 2V, 100Ah Vented / Flooded type Lead-acid secondary cells of C10 1 Set
discharge rate, in transparent containers, along with accessories (58 nos. cells)
and compatible spares having technical specifications as per
enclosed Annexure-A.
2. 2V, 100Ah Valve regulated Lead-acid cells of C10 discharge rate, 1 Set
along with accessories and compatible spares having technical (57 nos. cells)
specifications as per enclosed Annexure-B.

Above mentioned batteries shall be complete in general, electrical and functional requirements. Batteries
shall be supplied along with required battery mounting racks (multitier), fittings, accessories etc. The rack
shall be of suitable size, strength and provided with Sulphuric acid resistant treatment.

The batteries specified above shall be installed and used for 110V DC supply for substation protection,
control and backup auxiliary supply in various substations and UPS systems at RRCAT. Batteries shall
supply DC current under continuous and emergency conditions at the specified voltage. Fresh batteries
shall be offered against this tender requirement.

2. Submissions to be made along with the offer:

The following documents and details shall be submitted along with the offer.

2.1 The bidder shall be Original Equipment Manufacturer (OEM) or authorized dealer /supplier of
manufacturing firm for the batteries offered. The offered equipment should have been designed,
manufactured and tested as per relevant IS/IEC standards with latest amendments. If not OEM, the
dealer/supplier shall submit valid authorization letter of OEM for supply and after sale services for the
offered equipment.

2.2 Copies of the test report viz. test for capacity, test for voltage during discharge, efficiency tests and
other type tests as per relevant standards for offered batteries model/rating.

2.3 Duly filled Guaranteed Technical Particulars (GTP) sheet for various types of batteries, as per the
proforma given in respective enclosed Annexures-A & B. Any other particular/technical detail considered
necessary by the bidder may also be given.

2.4 Technical (catalogues/leaflets) sheets for batteries, associated rack system, placing arrangement at
site, battery layout drawings showing inter-cell, inter-row and tier connections for the offered batteries.

Note: Offer without copies of the above mentioned submissions (as per clause number 2) shall be
liable for summary rejection.

3. Submissions to be made along with the supply of material:

The supplier shall submit the drawings, bill of material (showing arrangement of battery bank), detail
catalogues and operator manual for carrying out regular operation & maintenance of the offered batteries.

4. Guarantee period: The guarantee period shall be minimum 24 months for both items of the tender.
Annexure-A
Technical specifications
For
Item No. (1) – Supply, installation testing and commissioning of 2V, 100Ah Vented / Flooded type
Lead-acid battery set

1. General requirements and standards compliance:


All the materials/components used for battery set shall be free from flaws and confirming to good
engineering practices. Except where modified by this specification, the offered batteries shall
comply with latest version of the standards specified below:

1.1 IS 1651 : Stationery cells and batteries, lead acid type.


(With tubular positive plates) – Specification.

1.2 IS 8320 : General requirements and methods of tests for


lead acid storage batteries.

1.3 IS 1146 : Specification for Rubber & Plastic


Containers for Lead Acid Storage Batteries.

2. Battery Specifications: brief technical specifications of the cells are as under.

2.1 Capacity at 270C : 100 Ah (C10 rate)

2.2 Nominal cell voltage : 2 Volt /cell


2.3 End Cell voltage : 1.80 Volt /cell.
55 Nos. + 3 Nos. spare cells with
2.4 Quantity of 2 Volt cells in each set: :
connectors
2.5 Container : Transparent SAN containers in
compliance with IS 1146.
2.6 Connectors ( inter Cell) : Lead coated copper connectors
2.7 Connectors ( inter row/inter tier) : Copper cable of suitable size
2.8 Nut-bolts : Lead coated brass or stainless steel
2.9 Electrolyte Batteries will be supplied along with
required quantity of electrolyte as per
IS: 266 and IS: 1069 in non-
returnable polyethylene Jerry cans
and packing cases. This shall also
include supply of 10% extra quantity
of electrolyte for futuristic use.
Electrolyte shall be tested for
sustained visual impurities before
pouring into the cells.

3. The scope of supply shall also include the following accessories and respective compatible spares
along with each battery bank set.

3.1 Accessories along with vented /flooded type battery set:


a) Double tier battery stand : Complete Set
b) Syringe type hydrometer : 1 No.
c) Thermometers : 1 No.
d) 3-0-3 voltmeter or multi-meter : 1 No.
e) Insulated spanners for connectors. : 1 No.
f) Acid resistant jug and funnel. : 1 Set
j) Pack of petroleum jelly : 1 kg
k) Protective goggles : 1 No.
l) Rubber aprons : 1 No.
m) Rubber boots : 1 pair.
n) Wall type holder duly painted
suitable for thermo-meter and hydrometer : 1 No.
o) Rubber syringe : 1 No.
p) Rubber siphons : 1 No.
q) Rubber gloves : 2 pairs
r) Torque wrench : 1 No.

4. Installation at site:
Supplier shall depute the competent technical team for installation and commissioning of the
batteries at site. All required instruments, tools & tackles, transportation /shifting of battery set up to
site shall be arranged by the supplier. PPEs required for execution and safe working at site shall
also be arranged by the supplier. Packing material shall be shifted to nearby scrap collection point.

Dismantling of existing battery banks and shifting of the same up to a radius of 1 km. shall be in the
scope of supplier. Bidder shall carryout the installation of new battery banks as per the actual site
conditions and as per the directions of Engineer-In-Charge. The battery banks shall be connected
with existing battery chargers using available cables.

Each cell in battery set shall be properly placed, balanced and provided with cell number stenciling
as per applicable Indian Standard.

5. Testing:
The batteries shall be subjected to the testing/verifications as tabulated below.
S. No. Description of tests Stage of inspection Site for inspections
5.1 Verification of type tests report as per Pre-dispatch. At manufacturer’s
clause no. 12.1.1 of Indian Standard works site.
code 1651 (Latest edition).
5.2 Acceptance tests as per clause no. Pre-dispatch. At manufacturer’s
12.1.2 of Indian Standard 1651 works site.
(Latest edition).
5.3 (a) Verification of bill of material, After receipt of all At RRCAT.
including spares. material.

(b) Acceptance tests as per clause no. After installation.


12.1.2 of Indian Standard 1651
(Latest edition).

Complete testing shall be considered to be included in the offer and no additional charges shall be
payable in this regard.

6. Commissioning at site:

After performing successful testing, battery bank shall be commissioned by the bidder and shall
submit copy of the commissioning report to RRCAT.

Required electricity shall be made available free of charge during erection, testing and
commissioning of battery banks.
7. Site conditions (for bidder’s information):
7.1 General climatic conditions at site:

The offered batteries shall be suitable for satisfactory continuous operation under the following
climate conditions:
Max. ambient air temperature : 50˚ C
Max. daily average ambient temperature : 45˚ C
Max. yearly weighted ambient temperature : 35˚ C
Min. air temperature : (-) 5˚ C

7.2 Nature of loads:


The above battery bank is required to feed conventional substation loads like circuit breaker control
system, relays, protection system, circuit breaker spring charging system, metering, indications, etc.

7.3 Details of Float-cum-boost charger.


Battery will normally be connected with the existing float-cum-boost charger in float mode. In case
of excessive discharge battery will be connected manually in boost mode till getting fully charged.
Set value of voltage of charger in float mode: 120 Volt (2.18 Volt/cell) and in Boost mode: 146 Volt
(2.65 Volt/cell).
Guaranteed technical particulars (GTP)
For
2V, 100Ah Vented / flooded type Lead-acid battery set
(To be duly filled & uploaded along with the offer by bidder)

1) Capacity of battery cells at C10 hour rate:


2) Make & Model of the offered cells:
3) Method of connection between cells (bolted or brunt):
4) Recommended starting and finishing rates of charge:
5) Recommended trickle charging rates for different types of working:
6) The type and material of separators:
7) Material and thickness of container:
8) Amount and specific gravity of electrolyte per cell required for first filling:
9) Recommended specific gravity of electrolyte at the end of full charge:
10) Expected specific gravity of at the end discharge at 10 hours rate :
11) Overall dimension of each cell:
12) Internal resistance of the cell (in milli ohms):
13) Maximum boost voltage per cell (V) :
14) Trickle charge current (mA) :
15) Maximum boost current (A) :
16) Initial charging current (A):
17) Ah efficiency (Min.):
18) Watt hour efficiency (Min.):
19) Maximum permissible ambient temperature:
20) End cell voltage at 10 hr. discharge rate:
21) Overall size of battery stand and no. of tiers:
22) Quantity of electrolyte per cell (in litres):
23) Short Circuit current of battery bank in Ampere:
24) Weight of each cell complete with electrolyte in kg:
25) Expected average life of battery at 27 ºC.:
26) Guarantee period after commissioning:
27) Are the offered batteries eco-friendly: YES/NO
(Please supplement with technical details).
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Annexure-B

Technical specifications
For
Item No. (2) – Supply, installation testing and commissioning of 2V, 100 Ah Valve Regulated Lead
Acid (VRLA) battery set

The offered battery bank shall comprise of 2V, 100 Ah rating (C10 discharge rate) Valve Regulated
Lead Acid (VRLA) cells for stationary application, complying with following technical specification.

1. General requirements and standards compliance: All the materials/components used for battery
set shall be free from flaws and conform to good engineering practices. Except where modified by
this specification, the offered batteries shall comply with latest version of the standards specified
below:

1.1 IS 15549 : Stationery valve regulated lead acid batteries –


Specification.
Or
IEC 60896-Part 21 & 22 : Stationery lead acid batteries - valve regulated
Methods of tests & requirements

2. Battery Specifications and accessories: Brief technical specifications of the cells are as under.
S. No. Description Parameter/ Value
1. Capacity at 270C. 100 Ah, (C10 i.e. 10 hrs. discharge rate.
2. No. of 2 Volt cells/set 55 Nos. + 2 Nos. spare cells with connectors
3. End cell voltage 1.75 V/cell
4. Nominal system voltage 110V DC
5. Suitable for Application. Substation protection, control and
backup of control supply.
6. Container Made of Polypropylene Copolymer/ acrylonitrile butadiene
styrene, styrene-acrylonitrile or any other acid resistant plastic
material and shall have chemical and electro-chemical
compatibility. The other requirements of plastic container shall
be as per IS: 1146.
7. Cell lids Made of same material as that container and suitable either for
resin bonding type or permanently sealing type based on cell
sealing design. The tensile strength of the container and lids
material shall be such as that it is capable to handle the internal
cell pressure of the cells in the worst working condition without
bulging and cracking. The covers may be permanently fixed with
container by Hermetic Heat Sealing technique. 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.
8. Plates Pasted construction and of good workman-ship. Plates shall be
free from cracks, white patches and other imperfections. Overall
design shall ensure long life, durability, low maintenance and
trouble free operation of battery in cyclic as well as in float
applications.
9. Separators Built in lead plated copper and brass inserts. Terminals shall be
clearly identifiable with permanent markings. Suitably sealed at
leads to prevent leakage of any gas. Any gas leakage shall be
only through venting device provided.
10. Terminal posts Built in lead plated copper and brass inserts. Terminals shall be
clearly identifiable with permanent markings. Suitably sealed at
leads to prevent leakage of any gas. Any gas leakage shall be
only through venting device provided.
11. Connectors Lead coated copper connectors or flexible copper cable
connector (inter row and inter tier, associated nut-bolts, washers
etc.). Lead coating shall not be less than 25 micron. All inter cell
connectors shall be protected with heat shrinkable silicon
sleeves for reducing the environmental impact including a
corrosive environment.
12. Material of Nut-bolts Copper/ brass/stainless steel. Copper and brass effectively
/fasteners lead coated. Stainless steel shall be passivated to prevent
corrosion with acid.
13. Electrolyte Sulphuric acid and water used for preparation of electrolyte
shall confirm to IS: 266 and IS: 1069.
14. Pressure regulation Each cell shall be provided with self re-sealable pressure
valve regulation valve. The vent plug shall be made with suitable
grade of fire retardant plastic material. The valve unit shall be
such that it cannot be opened without a proper tool.
15. Flame arrestor 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.
Flame Arrestor shall be capable to defuse the Hydrogen gas
escaped during charge and discharge.
16. Markings As per IS: 15549/ IEC 60896-Part 21 & 22.
17. Mounting rack All batteries shall be mounted in a suitable multitier 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.
18. Accessories included 1) Thermometer : 2 No.
2) 3-0-3 Voltmeter : 2 No.
3) Torque wrench : 2 No.

3. Installation at site:
Supplier shall depute the competent technical team for installation and commissioning of the
batteries at site. All required instruments, tools & tackles, transportation/shifting of battery banks up
to site shall be arranged by the supplier. PPEs required for execution and safe working at site shall
also be arranged by the supplier.

Dismantling and shifting of existing battery bank up to a radius of one kilometer shall be in the
scope of supplier. Supplier shall carryout the installation of new battery banks as per the actual site
conditions and as per the directions of Engineer-In-Charge. The battery banks shall be connected
properly to existing battery chargers using available cables. Each cell in battery set shall be properly
placed, balanced and provided with cell number stenciling as per applicable Indian Standard. All
packing material shall be shifted to nearby scrap collection point at RRCAT site by the supplier.
4. Testing & commissioning:

Following tests shall be performed on batteries by supplier in presence of RRCAT representative:


S. No. Description of tests Stage of inspection Site for inspections
4.1 (i) Capacity test tests as per applicable Pre-dispatch. At manufacturer
standard i.e. IS 15549 or IEC 60896- works.
Part 21 & 22.

4.2 (i) Verification of bill of material, After receiving full At RRCAT.


including spares. quantity at site.

(i) Visual examination of containers, Acceptance


checking of dimensions and marking.
(ii) Test for voltage during discharge at
C10 rate.

Testing and commissioning shall be considered to be included in the offer and no additional
charges shall be payable in this regard. After performing successful testing, battery bank shall be
commissioned by the supplier and copy of the commissioning report shall be submitted to RRCAT.
**Required electricity shall be made available free of charge during erection, testing and
commissioning of battery banks.

5. Site conditions (for bidder’s information):

a) General climatic conditions at site:


The offered batteries shall be suitable for satisfactory continuous operation under the following
climate conditions:
 Battery room Ventilation method : Through exhaust fans
 Max. ambient air temperature : 450 C
 Max. daily average ambient temperature : 400 C
 Max. yearly weighted ambient temperature : 350 C
 Min. air temperature : (-) 50 C

b) Nature of loads:
The above battery bank is required to feed conventional substation loads like circuit breaker
control system, relays, protection system, circuit breaker spring charging system, metering,
indications, etc.

c) Details of Float-cum-boost charger.


Battery will normally be connected with the existing float-cum-boost charger in float mode. In
case of excessive discharge battery will be connected manually in boost mode till getting fully
charged. Settings of voltage in charger; float mode: 120 Volt (2.18 Volt/cell) and in boost mode:
146 Volt (2.65 Volt/cell).
Guaranteed technical particulars for 2V, 100Ah VRLA battery set
(To be duly filled and uploaded along with the offer by bidder)

1. Battery Type:
2. Applicable test standard :
3. Battery Rating (C10 at 27ºC):
4. Make & model of cells:
5. No of Cells:
6. Cell Dimensions:
7. Single Cell Weight:
8. Battery Set Dimensions (55 Cells):
9. Battery Bank Weight:
10. Ah Efficiency:
11. Max. allowable ambient temperature for safe operation of batteries:
12. Recommended max. period of storage:
13. Material of container:
14. Type of Separator :
15. Material of Tray:
16. Method of Connection between cells:
17. Type of Connectors:
18. Life Cycle/ average life( in years) of Battery:
19. Guarantee period after commissioning of batteries:
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