DOCUMENT No PCPL-0532-4-407-04-11 1.0 1.1 1.2 2.0 2.

1 SCOPE

BATTERY

SECTION - 4 PAGE: 1 of 7

This specification covers requirements of stationary lead acid storage battery complete with battery racks inter cell and inter tier connectors and all other accessories. In case of conflict between any section or clause of this specification and Data Sheet-A, the requirements of Data Sheet-A shall govern CODES & STANDARDS The design, manufacture and performance of equipment shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve VENDOR of this responsibility. The equipment shall conform to the latest edition of standards mentioned in Data SheetA. TYPE The battery offered shall preferably be one of the following types as mentioned in Data sheet A. i) ii) Sealed Lead Acid Battery Nickel Cadmium Battery

2.2 3.0

4.0 4.1

FEATURES OF CONSTRUCTION GENERAL The equipment offered shall be complete with all parts that are necessary or usual for the efficient operation of the equipment, whether specifically mentioned or not

4.2 4.2.1

SEALED LEAD ACID BATTERY The sealed batteries shall be a starved electrolyte type with electrolyte immobilised in a micro porous material to allow recombining of generated oxygen internally. The battery shall be completely explosion resistant. Shall tolerate freezing and shall not allow gases to escape during normal charging conditions. The battery shall not require any watering and be maintenance free. Plante' Positive Plates The plante' positive plate shall be cast solid in pure lead in one piece and shall have adequate mechanical strength. It shall be electrochemically formed and shall be capable of operating under normal working condition with out buckling or cracking. Welding together of small size lead castings or fully formed plates to form larger sizes will not be accepted.

4.2.2

4.3

Tubular Positive plate shall consist of suitable bar with spines cast of suitably alloyed lead to give adequate mechanical strength. Porous, acid resistant and oxidation resistant tubes shall be inserted one over each spine. After insertion, the tubes shall be adequately filled and packed with active material before their lower ends are closed by a common bar. The construction and material of the tubes shall be such as to reduce loss of active material and to withstand normal internal stresses developed during service. DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-11 4.4 Pasted Positive Plates

BATTERY

SECTION - 4 PAGE: 2 of 7

The pasted positive plates shall consist of either pure lead, low antimonial lead alloy or lead calcium positive grids; having double separation with a glass wool retainer mat or any other suitable material placed against the surface of the positive plates, for good service life. 4.5 Negative Plates The negative plates shall normally be of the box type. End negative plates, if of box type may be of the half pasted type. Pasted plates shall have adequate mechanical strength and shall be so designed that the active material is maintained in intimate contact with the grid under normal working conditions. 4.6 CONTAINERS The containers shall be made of plastics, or fibre reinforced plastics (FRP). The container shall be spill proof and leak proof, explosion resistant and increased safety type enclosure. 4.7 VENT PLUG The vent plug shall be for safety pressure vent and of self resealing type. The Vendor shall indicate the vent pressure value. 4.8 SEPARATORS The plate separators shall consist of a micro porous matrix, which shall serve as the mobiliser for the electrolyte. The battery separator shall maintain the electrical insulation between the plates and shall allow the electrolyte to permeate freely. The VENDOR shall indicate the material of the separator. 4.9 CONNECTORS AND TERMINAL POSTS Inter cell and inter-tier connectors and terminal posts shall be of copper. Terminal posts shall be designed to accommodate external bolted connection conveniently and positively. Each terminal post shall have two bolt holes of the same diameter, preferably at right angles to each other. The bottom hole shall be used to terminate the inter cell connection. The top hole shall be left for PURCHASERS terminal connections. All the metal parts of the terminals shall be lead coated if necessary. The VENDOR shall indicate this in the bid. The junction between terminal posts and cover and between cover and container shall be so sealed as to prevent any seepage of electrolyte. 4.10 ELECTROLYTE The electrolyte shall be battery grade sulfuric acid conforming to latest editions of relevant standards. The sealed battery shall be transported with the electrolyte immobilized and fully charged. 4.11 NICKEL-CADMIUM BATTERY 4.11.1 The battery container and lid shall be alkali resistant no-aging material with high impact strength. It shall have smooth sides except for receptacles., hold down br, vent tubes, name plate, latches and polarity marking.

DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-11

BATTERY

SECTION - 4 PAGE: 3 of 7

4.11.2 The cell container shall be of high strength alkali resistant material either nickel plated mild steel/ stainless steel or non-porous plastic as specified in Data Sheet-A 4.11.3 The connector covers shall be of hard PVC to prevent external short circuiting. 4.11.4 The venting device shall be of anti splash type and shall allow the gases to escape freely and shall effectively prevent the electrolyte from coming out . Provisions shall be made for drawing electrolytes samples, checking and topping of the electrolyte. 4.11.5 The electrolyte used shall be a solution of potassium hydroxide in distilled water or demineralised made up to the specific gravity at 27O C. 4.11.6 Cell Designation. Vented Nickel-Cadmium prismatic rechargeable cells shall be designated by letter K followed by second letter: T P S L M H X Cells with tubular plates Cells with pocket plates cells with sintered plates For low rate of discharge (below 0.5 Cs) For medium rate of discharge (0.5 Cs to 3.5 Cs) For high rate of discharge (3.5 Cs to 7 Cs) For very high rate of discharge (above 7 Cs)

The second letter shall be followed by a third letter:

4.11.7 The group of three letters shall be then followed by a group of figures indicating Amphour capacity. Cells in plastic material shall be marked with letter 'P'. 4.11.8 Separators used for the cells shall be porous alkali resistant and high insulating capacity to avoid shorting on leakage of the current between the plates of opposite polarity. The separator shall be dimensionally stable with out deformation at the room temperature. 4.12 ACCESSORIES The battery shall be complete with accessories and devices, including but not limited to the following: i) ii) iii) iv) v) Battery racks Porcelain insulators, rubber pads etc. Set of inter cell, inter-tier and inter bank connectors as required for the complete installation. Electrolyte for first filling +10% extra in plastic bottles or drums, for Ni-Cd battery. Accessories for testing and maintenance. a) One - -3, 0, +3 volts Dc voltmeter with suitable leads for measuring cell voltage. DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-11 b) c) d) e) f) g) h) i) j) k) l) n) o) p) q) 5.0 5.1

BATTERY

SECTION - 4 PAGE: 4 of 7

One -Hydrometer for measuring specific gravity of electrolyte in steps of 0.002. One - Filler hole thermometer fitted with plug and cap and having specific gravity correction scale. Three -Pocket thermometers Two sets - Funnels or siphon hydrometer and plastic jugs for topping up. Two Graduated plastic level test tube for electrolyte level checking. Two PVC aprons Four- PVC GLOVES and any other protective wearing apparel to be specified by VENDOR Two- Cell lifting straps One set Terminals and cable boxes with glands for connecting cable as required. Spare connectors Spare vent plugs Suitable set of spanners PVC spill trays under the Battery cells One set - Cell topping up apparatus (for large sizes of NI-CD cells) VENDOR shall list the items. Insulated wrencher (for sealed lead acid battery).

m) Spare nuts and bolts

BATTERY LAYOUT Unless otherwise specified the battery shall be complete with battery racks and preferably mounted in single tier arrangement. VENDOR shall furnish dimensioned drawings of the battery layout for purchasers APPROVAL. For smaller units, utilising sealed-in type of batteries, mounting of the battery in the same sheet metal cubicle as the associated equipment, for instance battery charger, will also be acceptable. BATTERY RACKS Battery racks shall be constructed from good quality teakwood and painted with two coats of approved alkali resisting paint. The construction of the racks unless otherwise mentioned in Data Sheet-A shall be suitable for fixing to a flat concrete floor. The racks shall be rigid, freestanding type and free from warp and twist. The completed racks shall be suitable for being bolted end to end to form a continuous row. Insulators shall be provided below the legs of the stands.

5.2

5.3

VENTILATION THE bidder shall INDICATE IN THE TENDER REQUIREMENTS OF VENTILATION IN THE BATTERY ROOM. The battery shall operate satisfactorily DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-11

BATTERY

SECTION - 4 PAGE: 5 of 7

over the entire range of temperature indicated in Data Sheet without affecting its normal life. BIDDER shall indicate the percentage reduction in battery capacity at the lowest temperature compared to that tat standard temperature of 27O C. If any special ventilation requirements are necessary, the same shall be indicated. 6.0 CAPACITY The standard ampere-hour capacity at ten hour rate of discharge of the battery has been based on the requirements of loads mentioned in Data Sheet-A and the minimum ambient temperature specified. BIDDER SHALL Guarantee that the capacity of the battery offered by him is adequate for the duty specified (all loads being co-incident from the instant of supply failure even at the minimum ambient temperature specified in Data Sheet-A). For lead acid battery it may be assumed that the battery is fully charged to 2.15 V at the start of the cycle and is discharged to a voltage of 1.75 V/cell at the end of the cycle. For Ni-Cd battery each cell at start is considered charged to 1.28 V and the cell end voltage after discharge to be 1.1. or 1.05 V as mentioned in Data Sheet-A 7.0 7.1 7.2 CHARGING The proposed method of charging of the battery is indicated in the Data Sheet A. BIDDER shall state whether an equalising charge is recommended for the battery. If so, the equalising charging voltage, current, duration and the interval between the equalising charging shall be specified in Data Sheet-B. BIDDER SHALL also indicate the requirements for boost charging. LIFE The BIDDER shall quote in his offer the guaranteed life of the battery when operating under the conditions specified 9.0 9.1 TESTS All tests shall be conducted as per the relevant standards. Tests shall include following Type & acceptance tests: i) Type Tests: Copy of report on type test performed at MANUFACTURERS works shall be submitted with the bill.

8.0

ii) Acceptance Test: Performed at site after installation and commissioning of the battery. All tests shall be witnessed by the PURCHASERS representative. Details of tests to be performed are given below: 9.2 9.2.1 TYPE TESTS Type tests shall comprise o the following: a) Visual inspection b) Dimensional check c) Capacity tests d) Retention of charge test e) Ampere-hour and watt-hour efficiency tests.

DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-11 f) Endurance test g) Life cycle test 9.2.2

BATTERY

SECTION - 4 PAGE: 6 of 7

Type tests shall be conducted on a minimum of one sample cell typical and identical with the cells forming the complete battery offered. However, the test cell shall not be one of the cells offered in the battery offered.

9.2.3. In applications where the first momentary discharge stated in Data Sheet-A is high and lasts for several minutes a high discharge test shall be conducted, in addition to the above tests, as a type test. This test shall ensure that at the end of the high discharge rate duty, end cell voltage does not fall below 1.6 V for lead acid and 1.1/1.05 V for Ni-Cd and the temperature rise of electrolyte shall be within 10O C. 9.3 ACCEPTANCE TESTS Acceptance tests shall be conducted at site on completion of installation and commissioning and immediately prior to putting the battery in service. These tests shall comprise of: a) Visual inspection b) Dimensional check c) Capacity test d) Test for voltage during discharge e) Storage test f) Insulation resistance 9.4 TEST REPORTS A copy of routine and type test results shall be submitted for approval before the dispatch of batteries. Specified number of bound copies of complete test results shall be furnished with the batteries. 10.0 SPARE PARTS BIDDER shall include the following items in his recommended list of spares along with item wise unit prices: a) Inter cell connectors b) Battery stand insulators and cell insulators c) Nuts, bolts, washers etc. d) Vent plugs cum level indicators e) Complete set of spare cell (without electrolyte for Ni-Cd cell) f) Battery inter row connector g) Battery intercell connector 11.0 IDENTIFICATION Each cell shall be marked in a permanent manner to indicate the following information: DATE:22-06-2006 ISSUE No: P0

DOCUMENT No PCPL-0532-4-407-04-11 a) Cell number b) Type of positive plate

BATTERY

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c) AH capacity at 10 hour rate (lead Acid) and 8 hour rate (Nickel-Cadmium). d) Type of container e) MANUFACTURERS name f) Month and year of manufacture. 12.0 CO-ORDINATION WITH BATTERY CHARGER VENDOR When battery charger is procured separately, VENDOR shall coordinate with battery charger VENDOR in regard to layout, connections, charging voltage requirements etc. 13.0 TRANSPORT The Ni-Cd battery shall be transported without electrolyte in preferably dry charged condition. The electrolyte shall be supplied separately in non-returnable containers. The sealed lead acid battery shall be transported with the electrolyte immobilized, sealed and fully charged. 14.0 WARRANTY VENDOR shall indicate if he will give a warranty period of 10 years for sealed lead-acid battery and indicate the warranty terms and conditions.

DATE:22-06-2006 ISSUE No: P0