Technical Specification for Battery

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TECHNICAL SPECIFICATION

FOR PLCC BATTERYGENERAL :

This Specification covers the manufacture, testing before despatch and delivery

FOR(D) of Lead-Acid Stationary Battery sets conforming to ISS 1651/1991.

The materials used for the manufacture of the Lead AcidBattery sets shall be of best class and capable of satisfactory operation ontropics with humid atmosphericcondition without distortion (or) deterioration. The workmanship shall be ofhighest grade and the entire works in accordance with the best modern practice.

I. TECHNICAL SPECIFICATIONS:-

i) Type : Lead-Acidii) Positive Plates : Tubular platesiii) Negative Plates : Pasted platesiv) Connector : Lead plated copper connector and

Lead plated Brass nuts, bolts and washers.v) Initial charging : Conforming to IS:1651/1991vi) Accessories : Teak wood stand, cell stand insulators,

cell number plates.

2 Nos. Syringe Hydrometers, Battery Thermometer

and 3V-0-3V cell testing voltmeter shall besupplied in the accessories with battery set. Itmay be noted that the voltmeter shall be ofaccuracy class not inferior to 0.5 and theresistance shall be atleast 1000 Ohms per

Volt. The Thermometer shall be for measuringappropriate temperature and one division of thegraduated scale shall represent at the most1Degree "C". The accuracy of calibration shall benot less than 0.5 Degree "C".The Hydrometershall be provided with graduated scale onedivision of which shall represent at the most0.005 unit of Specific Gravity. The accuracy andcalibration shall not be less than 0.005 unit ofSp. Gravity.

vii) Capacity : The capacity of the Batteries are at 10Hrs dischargerate to an end voltage of 1.85V per Cell. The batteriesare assembled with tubular positive, pasted negative

plates and microporous PVC separators in wrappedhard rubber containers complete with acid level


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indicating floats, connectors, Bolts, nuts andwashers as per IS 1651/1991. The battery setsshall be supplied with battery stands made out ofseasoned Teakwood, stand insulators, cellinsulaltors and Inter-row cell connectors, in dry

uncharged condition and acid for filling in separatecontainers (with 10% excess) as per IS 1651/1991.

viii) Insulation : The internal insulation of the cell shall be such as tostand the heavy wear & tear. The separators shall notsplit (or) crush under heavy strain (or) discharge.

ix) Terminals and : Batteries with individual cells connectors in seriesConnectors by welding, soldering will not be accepted.The connectors should be such as to facilitateeasy isolation of any cell, when necessary, for

purpose of maintenance and shall be made oflead. Copper connectors suitably coated with lead towithstand corrosion due to sulphuric acid shall be usedwhere the cells are called upon to dischargeat very high rates. Bolts, nuts and washers forconnecting the cells with intercell connectorsshall be robust, made of brass material andeffectively coated with lead to prevent corrosion.

x) Wooden Stand : The stand shall be for single tier two row cell

arrangement for all the battery sets. The stand shallbe made of seasoned teakwood and shall besupplied well finished but without painting. However, inorder to apply three coats of anti-corrosive black paintsubsequently sufficient quantity of anti-corrosiveblack paint in separate containers shall besupplied with each stand. TNEB will arrange to paintthe stands made of Teakwood. The drawing of thewooden stand may be furnished. If any change in thedimensions of the wooden stand is required, the samehas to be incorporated to meet the requirements.

xi) Electrolyte: 10% excess electrolyte in carboys for initial charging.The specific gravity of electrolyte supplied for the initialcharging of the batteries shall be uniform andsuch as to obtain the required value i.e. 1.200 (or)as per specification of the manufacturer, equally in allthe cells after the completion of the first chargeitself. It shall not necessitate adding concentratedacid for obtaining required specific gravity later.

xii) Cell containers: The containers shall be of moulded (or) wrapped Hard

rubber and shall conform to IS 1146/1981. The TypeTests for containers conforming to the requirements


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as per IS 1146/1981 may be furnished. Thecontainers shall be designed such that they do not crack(or) become leaky and shall withstand normalconditions of service and will resist any acid action onthem.

The Technical particulars are specified in Annexure.

PART - I

TECHNICAL GENERAL

1.0 TEST CERTIFICATE :


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1.1 Test Certificates in triplicate for the materials furnishing the results of thetests as per latest issue of ISS shall be forwarded and got approvedbefore the materials are despatched. In addition to the tests called forin the specification the purchaser reserves the right of having such testsas he desires carried out at his own expenses to satisfy himself that the

materials conform to the requirements of this specification. The materialsmay be rejected if the test results are not satisfactory. The type testcertificates (photostat copies) as per latest ISS shall be furnished with thetender for reference and date of type test shall not be later than 5-yearsperiod. (Refer inspection clause 8 also for the details of inspection/ tests.)

2.0 ROYALTIES AND PATENTS :2.1 All Royalties for patents or the charges for the use or

infringements thereof that may be involved in the contract shall be includedin the tender prices. The tenderer shall protect the purchaser against any

claim thereof.

3.0 GUARANTEED PARTICULARS:

3.1 The tenderer shall furnish all the particulars of the materials offeredagainst this specification. Unless full details are furnished, the tender maynot be considered.

4.0 DEPARTURE FROM SPECIFICATION:

4.1 Should the tenderers wish to depart from the provisions of this specification,he shall list such departures separately and submit full particulars and

reasons for the departure in the form enclosed to part II of thisspecification. Unless this is done, the materials offered shall be consideredto comply in every respect with the terms and conditions of thisspecification.

5.0 RESPONSIBILITY:

5.1 The tenderer is responsible for safe delivery of the materials at thedestination stores. The tenderer should also include and provide forsecurity, protecting and packing the materials so as to avoid damages orloss in transit.

6.0 PACKING :

6.1 The packing may be in accordance with the manufacturer's standardpractice. The contractor should however ensure that the packing issuch that the materials reach their destination without damages aftertransport by Rail or Road.

7.0 MAXIMUM WEIGHTS AND DIMENSIONS OF PACKINGS:

7.1 The contractor is responsible for informing himself of the facilities thatexist for road and rail transport to site, the maximum packages which can

be conveyed by the Railway and crane lift available at the destination


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railway station. The contractor is also responsible for any loss or damageduring transport.

7.2 Each case or package should be clearly marked and should containdetailed packing list.

8.0 INSPECTION :8.1 The accredited representatives, of the purchaser shall have access to the

contractor's works at any time during working hours, for the purpose ofinspecting the manufacture of the materials and for testing the selectedsamples from the materials covered by this specification. The contractoror the sub-contractor shall provide facilities for testing such samples as perstandards agreed between the supplier and the purchaser.

8.2 The tenderer shall specify the international standards which are applicablefor the equipments to be quoted under this specification.

8.3 The purchaser reserves the right to conduct any other reasonable testsat manufacturer's premises or at site. The purchaser shall be supplied with2 copies of test result. A separate copy of type and routine tests to becarried out on the equipments shall be enclosed with the Tender.

8.4 Tenderers are requested to furnish in their tenders the exact location oftheir factory with address to enable inspection by Board if considered

necessary.

8.5 It should be supplier's responsibility to arrange for inspection, despatchetc., in time to keep up the delivery schedule. A reasonable time of atleast15-days shall be given to the Board for arranging inspection.

9.0 QUALITY PLAN :

9.1 You will prepare, submit and discuss with us, and based on suchdiscussions finalise within 30 days (thirty days) from the date of the letter ofintent detailed quality plans in the format as given in Schedules for allcomponents of the equipments manufactured by you setting out during thevarious stages of manufacture the quality practices and procedures to befollowed by your quality control organisation, the relevant referencedocuments/standards/ acceptance level, inspection documentation raisedetc. In these quality plans we will identify "Hold Points" beyond whichwork will not progress without our consent in writing. For thecomponents/equipments procured by you for the purpose of this contractyour purchase specifications and enquiries shall call for such quality plan ofthe successful vendor which shall be discussed and finalised by you,in association with us, in the aforesaid manner and the same shall form partof your purchase order on your sub vendor. We also reserve our right to

carryout quality audit and quality surveillance of the system and proceduresof your/your vendor's quality management and control


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activities. However, such audit/ surveillance by us shall not relieve you ofany of your responsibilities under the terms of contract.

10.0 COMPLETENESS OF TENDER :

10.1 The tender should be complete with all details of illustrative &descriptive literature and drawings. The tenderers shall furnish thecomplete technical details of the equipments. Information regarding thecountry of manufacture or origin of materials used in the manufactureof the articles should be furnished. The tenderer should include allminor accessories even though not specifically mentioned in thisspecification but which are essential for the completeness of thematerials ordered and which are required for efficient operation for theequipment ordered. The tenderer shall not be eligible for any extracharges in respect of such minor accessories though not included in the

tender.

11.0 INTERCHANGEABILITY :

11.1 All similar parts and removable parts of similar items shall be interchangeablewith each other.

QUANTITIES :

12.1 The quantities mentioned in this specification are only approximate. Thepurchaser reserves the right to revise the quantities at the time ofplacing the order to an extent of +/- 25%.

13.0 DESPATCH OF MATERIALS :

13.1 Despatch of items should be done only after approval of test certificates.The railway destination and the name of the officers to whom advanceintimation regarding despatch to be sent will be intimated by the consigneesin the despatch instructions.

14.0 CLIMATE CONDITIONS :

14.1 The materials are for use in Tamil Nadu and the materials should besatisfactory for operation under tropical conditions in Tamil Nadu.

1. The ambient temperature will be within the range of 10 to 50 deg.C2. The altitude will be less than 2000 metres.3. The maximum atmospheric humidity will be in the range of 100%4. Average number of thunder storm days per annum - 65 days.5. Average number of dust storm days per annum- 5 days.

6. Average number of rainy days per annum - 65 days.7. Average annual rainfall - 10 cm.


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8. The climatic conditions are prone to wide variations in ambientconditions and equipments offered under this specification shall besuitable for installation at the Sub-station Control Rooms, CarrierRooms & Power Houses as detailed elsewhere in this specification.

9. All electrical devices shall be given tropical and fungicidal

treatment, for smoke and mild acids are also present in theatmosphere.

15.0 ELECTRICITY RULES :

15.1 All works shall be carried out in accordance with the latest provisions ofthe Indian Electricity Act and the rules there under unless modified bythis specification.

16.0 EQUIPMENTS/MATERIALS AND WORKMANSHIP :

16.1 All the equipments shall be of the best class and capable of satisfactoryoperation in the tropics with humid atmospheric conditions withoutdistortion or deterioration. Unless otherwise specified the equipmentshall conform to the requirements of the appropriate Indian or I.E.C. orother national Standards. Where a specification covering theequipments in question has not been published, the tenderer should specifyto what extent they would be in a position to accept the various provisions

in the specification.

16.2 The workmanship shall be of the highest grade and the entire construction inaccordance with the best modern practice. The whole of the work shall be ofthe highest class throughout well finished and of approved make. Theentire design and construction shall be capable of withstanding theseverest stresses likely to occur in actual service and of resisting roughhandling during transport.

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ANNEXURETECHNICAL PARTICULARS.

LEAD-ACID STATIONARY BATTERIES IS1651/1991-------------------------------------------------------------------------------------------------------------

Sl. Description 48V/120 AH 48V/250 AH 48V/400AHNo.----------------------------------------------------------------------------------------------------

1. Make & Type :


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2. Capacity : 120AH AT 250AH AT 400AH AT10 HRS. 10 HRS. 10 HRS.

3. Number of cells in Battery 24 NOS. 24 NOS. 24 NOS.set

4. Discharge capacity at 3 Hrs. : 86AH 179.25AH 287AH

Rate for end volt 1.8 volt.5. Discharge capacity at 10 120AH 250AH 400AH

Hours Rate for end voltage1.85 volt

6. Normal charging rate : 6 A 15 A 24A7. Maximum charging rate : 12 A 30 A 48A8. Normal charging time after 12-14 HRS. 12-14 HRS. 12-14 HRS.

complete discharge9. Recommended current 6 Amps. 15 Amps. 24Amps.

For initial charging10. Time required for initial 100 Hrs. 100 Hrs. 100 Hrs.

charging at the above current11. Watt-Hour efficiency when 75% 75% 75%

discharged at 10 Hours rate

12. Number of rows : Double row Double row Double rowused for the stand

-------------------------------------------------------------------------------------------------------Sl. Description 48V/120 AH 48V/250 AH 48V/400AHNo.--------------------------------------------------------------------------------------------------------13. Approximate weight of Lead : 5.5 Kg. 11.00 Kg. 17.4

Kg. required per cell (kg)


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14. Approximate weight of : 0.175Kg. 0.325Kg.0.525Kg.Antimony per cell

15. Type & Material of : PVC Envelope PVC Envelope PVC Envelopeseparators

16. Material of containers : Hard Rubber Hard Rubber Hard Rubber17. Amount and specific gravity : 3.7 Lit. 8.5 Lit. 12.2 Lit.

of electrotyle required per 1.190 SG 1.190 SG 1.190 SG cellfor first filling at 27 Deg.C at 27 Deg.C at 27 Deg.C

18. Recommended specific gravity : 1.200 1.200 1.200at the end of a full charge

19. Expected specific gravity at : 1.095 1.095 1.095the end of the discharge at the specified rate ( 0.015%)

20. Recommended trickle charging 120-480mA 250-1000mA 400-1600 mArate for different type of

working21. Overall dimensions of each : As per IS 1651

cell and complete battery set.

22. Distance between centres of : As per IS 1651cells when erected.

23. Weight of cell complete with : As per IS 1651Acid.

24. Recommended Maximum period : 2 Year 2 Year 2 Yearof storage (dry uncharged)

25. Internal resistance of cell : 1.60 m 0.795 m 0.535 m

-------------------------------------------------------------------------------------------------------Sl. Description 48V/120 AH 48V/250 AH 48V/400AHNo.-------------------------------------------------------------------------------------------------------Testing Equipments:1. Voltmeter:a) accuracy class 0.5b) resistance per volt 1000 Ohms per volt2. Hydrometer:a) graduationsreading possible. Min. 0.0053)Thermometer:a) Range: 0 to 100 Deg.Cb) Graduation: 1 Deg.C Min.

temperature possible


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Technical Specification for Battery

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