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1.5.1.6.6.01-Rev.

D.C. SUPPLIES
INDEX
SECTION

TITLE

GENERAL

DC SYSTEM ARRANGEMENT

TYPE OF BATTERY

INITIAL CHARGE AND TEST DISCHARGE

BATTERY DUTY

BATTERY MOUNTING CONNECTIONS AND


ACCESSORIES

CONTROL AND CHARGING EQUIPMENT

DISTRIBUTION SWITCHBOARDS

ROUTINE, TYPE AND FUNCTIONAL TEST AT


MANUFACTURER'S WORKS

9.1

GENERAL

9.2

TYPE TEST AND ROUTINE TEST

10

LIST OF STANDARDS

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(D.C. SUPPLIES)

1.5.1.6.6.01-Rev.6

D C SUPPLIES
1

GENERAL

D.C. auxiliary power supply shall be provided as below: a) 110 volts, Battery and Charger - Main station battery and charger for protection,
alarms, indication, control of switchgears & transformers and Digital Control
System (DCS)/SCS System as applicable. Typical arrangement of 110V DC station
supplies is shown on drawing STND/3/S/00400.
b) 110 volts, Battery and Charger for Substation Emergency Lighting shall be identical
in all respect to Item 1 (a) above except that battery and charger shall be single set
instead of dual set.
Refer to Civil and Building Works specification 1.5.3.1.0.01, clause 23.26 for
Emergency Lighting design, loads and application.
c) 48 volts, Battery & Charger for SCADA & Communication, refer to document
1.5.1.5.9.03, which will over ride this document wherever applicable.
d) 24 volts, Battery and charger - for Fire protection system, refer to document
1.5.1.9.0.08, clause 2.0 for design, loads and application.
Ratings to meet the requirements outlined under "Battery Duty" must be approved by
the Engineer before materials are ordered.
The battery systems for emergency lighting, fire protection, SCADA and
communications equipment are covered in other sections of this Specification.
Each of the two 100% duty batteries shall be located in a separate mechanically
ventilated room. At least two heavy duty and explosion proof exhaust fans for each
battery room shall be provided along with the electrical interlock to operate
automatically with an adjustable timer. Free discharge of gas from battery room is a
must.
Storage facilities shall be provided for electrolyte, distilled water and
maintenance equipment. Surface finishes in the battery rooms shall be to the approval
of DEWA. Special sink (acid/alkaline resistant) as well as Eye wash equipment
together with water facility to be provided in each battery room. Safety signs related to
batteries and Electrolyte handling shall be displayed within as well as outside of each
battery room.

D.C. SYSTEM ARRANGEMENT


The nominal D.C. system voltage shall be as stated above and the voltage measured at
the main distribution switchboard shall not vary by more than plus 10 per cent and
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1.5.1.6.6.01-Rev.6

(D.C. SUPPLIES)

minus 15 per cent of the nominal voltage under all charging conditions when operating
in accordance with the requirements of this Section.
Duplicate 100% duty battery shall be connected to duplicate 100% duty chargers,
having boost and float facilities, in such a way that either charger can be disconnected
without interrupting the output of the other charger or the battery.
Each system comprising of battery, charger and DCDB must be rated to take entire load
individually. Two sets of charger and Battery shall be used one for main D.C supply
and the other for alternative supply in case of failure of one. Under normal condition
D.C distribution circuits are through the MCB's only and the fuses for alternate supply
are kept `out and suitably safeguarded through proper protection covers '. Fuses for
alternate supply would be used only when the concerned MCB's are `OFF'. Fuse and
breaker numbers must correspond to each other and the fuse of a particular breaker
shall be located in the same cabinet in order to minimize interruption time during the
change over process. Rating of D.C. distribution MCB and concerned Fuse for alternate
supply should be the same. Ratings of Main switches and Replaceable type HRC fuses
should be the same, and sufficient enough to carry the entire load and designed for
maximum short circuit current.

TYPE OF BATTERY
The battery shall be of the Nickel Cadmium pocket plate type complying with IEC
60623. The battery shall be designed for a life expectancy of 25 years under the
conditions specified in document 1.1.0.0.0.01 for General Design Criteria
Battery cases shall be indelibly marked with maximum and minimum electrolyte levels.
Translucent case of battery is preferred for visible from outside the electrolyte level and
plate condition. Vent caps shall be of flame retardant type.

The electrolyte shall be free from impurities and the Potassium Hydroxide used shall
comply with BS.5634. Dilution of the alkaline electrolyte and topping up of cells shall
be carried out using distilled water only.
Battery Cells shall be numbered consecutively (following continuous serial numbers).
Numbering of cells shall be permanent or by means of adhesive stickers. Stickers shall
be of durable/alkaline resistant material, which shall be pasted on the battery racks
subsequent to installation/commissioning at site. Terminal cells shall be marked to
indicate polarity as per IEC 60 623.
The main lugs of the battery shall be designed to facilitate external connection of the
temporary battery charger to the system.
Cells shall be permanently marked with the following information as a minimum:
a)
b)
c)

Manufacturers reference number and code


Type of cell
Nominal Volts
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(D.C. SUPPLIES)

d)
e)
f)
g)

1.5.1.6.6.01-Rev.6

Nominal Capacity at 5-hour rate


Type of Electrolyte
Year of Manufacture
DEWA Contract

The electrolyte capacity and general design of the cells shall be such that inspection and
maintenance, including topping up of the electrolyte, shall be at intervals of not less
than twelve months.
4

INITIAL CHARGE AND TEST DISCHARGE


The Contractor shall be entirely responsible for carrying out and completing the initial
charge, test discharge and subsequent re-charge of the battery. The Contractor shall
provide continuous supervision during this time. The Contractor shall provide
resistors, instruments, leads, and the apparatus necessary for the initial charge, test
discharge and subsequent recharge of the battery.

BATTERY DUTY
The battery cells shall be of high rate of discharge (H) type complying with IEC 60623.
The final cell voltage shall be 1.1 Volts . The AH capacity shall be determined on the
basis of the following consideration: Standing dc loading shall comprise protection, control, lighting, indications, Digital
Control System (DCS)/SCS System, Fault recorder system as applicable and alarms.
This loading shall be determined from all equipment to be supplied on this contract. In
addition the future circuit requirements estimated on the same basis as the present
requirements.
Ampere-hour capacity for the above specified discharge rate should be calculated on
the basis of the following additional intermittent loading.
(a)

Two closing operations on all circuit breakers (including future) supplied by


the battery.

(b)

Two tripping operations on all circuit breakers (including future) supplied


by the battery. Wherever busbar protection is provided, it shall be assumed
that all circuit breakers in all busbar protection zones trip simultaneously.

(c)

Charging of dc motor wound circuit breaker closing springs (where


applicable) to enable the closing operations to be carried out.

(d)

A spare capacity of 25%

(e)

An ageing factor of 1.25 shall be considered as a safety margin as per IEEE


Standard 1115-1992, Recommended Practice for Sizing Nickel-Cadmium
Batteries for Stationary Applications.

(f)

Temperature de-rating factor shall be taken as per recommendations of the


battery manufacturer.
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1.5.1.6.6.01-Rev.6

(D.C. SUPPLIES)

All quantities derived in this manner shall be quoted in the Tender, but shall not be
used for ordering materials until specifically approved by the Engineer. Detailed
calculations and loading characteristics on which these are based shall be submitted to
the Engineer at the engineering stage. All calculations shall be based upon actual
loadings and not on the assumed loads. Necessary documents shall also be submitted
in support of the calculations.
6

BATTERY MOUNTING CONNECTIONS AND ACCESSORIES


Batteries shall be placed on insulated racks cabinets made of sheets of material, which
shall be acid/alkaline resistant. The cells shall be arranged so that each cell is readily
accessible for inspection and maintenance, and it shall be possible to remove any one
cell without disturbing the remaining cells. The stands shall be so dimensioned that the
maximum height of the upper tier (if provided) shall not be more than one meter and
bottom of the lower tier will not be less than 300 millimeter from the ground.
Necessary calculations shall be submitted to ensure proper ventilation of the battery
rooms in order to avoid accumulation of hazardous gases in the battery rooms.
Batteries shall be supplied and erected complete with all necessary connections and
cabling. Connections between tiers, between end cells and between porcelain wall
bushings shall be by PVC cables arranged on suitable racking or supports. Before
jointing, joint faces shall be bright metal, free from dirt, and shall be nickel-plated and
protected by a coating of petroleum jelly. Terminal and inter-cell connections shall be
of high conductivity corrosion free material.
Cartridge fuses shall be provided in both positive and negative leads and positioned as
close to the battery as possible and shall be rated for at least three times the maximum
battery discharge current at the highest operating voltage. The two fuses shall be
mounted/separated through insulated barriers. Battery fuse box shall be spacious
enough to accommodate armored cables. Suitable labeling shall be provided on the
battery and charger cable terminations within the battery fuse box.
Warning labels shall be fitted to warn personnel of the danger of removing or replacing
a fuse whilst the load is connected and that fuses should not be removed immediately
following boost charge due to the possible ignition of hydrogen gas. In case of
providing a battery isolator, arrangements shall be made to provide status indication
for the same.
It shall not be possible to leave the battery disconnected (by means of switches or
removal or operation of fuses) without some local and remote indication that such a
state exists. Trip fuse mechanism shall not be acceptable to initiate/actuate fuse fail
alarm system.
The maintenance equipment shall comprise of the under mentioned items as a
minimum: a)
One cell testing voltmeter of suitable range.
b)
Two syringe hydrometers of suitable range
c)
Two electrolyte-pouring funnels
d)
Two thermometers of suitable height and range.
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(D.C. SUPPLIES)

e)
f)
g)

1.5.1.6.6.01-Rev.6

Two pairs of rubber hand gloves.


One rubber type safety apron.
Two safety goggles.

Other items necessary for the erection and correct functioning and maintenance of the
equipment shall be provided for each station.
7

CONTROL AND CHARGING EQUIPMENT


Each battery charging equipment shall comply with the requirements of BS.4417 (IEC
60146) and shall be of the thyristor controlled automatic constant voltage type with
current limit facilities and shall be suitable for supplying the normal constant load and
at the same time maintaining the battery to which it is connected in a fully charged
condition. All equipment shall be naturally ventilated or provided with ventilating
fans wherever deemed to be necessary.
All the equipment for each charger shall be contained in a separate ventilated steel
cubicle. The charger cubicles shall normally be mounted immediately adjacent to the
dc distribution panel to form a board and shall be of matching design colour and
appearance.
Chargers shall be rated for 231/400V a.c. for following variations in input supply: -

Frequency variation - 49.5-50.3 Hz.


Voltage variation - 10%

The mains transformer shall be of a suitable rating and design. Clearly marked offcircuit tapings shall be provided on the primary windings and change of tapping shall
be by means of easily accessible links. The transformer shall be of the natural air-cooled
type capable of operating continuously at full load on any tapping with the maximum
specified ambient temperature.
All rectifiers and semi-conducting devices employed in the charger shall be of the
silicon type. They shall be adequately rated, with due regard to air temperature within
the charger enclosure, for the maximum ambient temperature. Charger shall be
provided with the input and output fuses in addition to isolators.
The rating of the charger on float/boost charge mode shall be equal to the battery
standing load including 25% as design margin plus the battery charging current
numerically equivalent to 0.2 x C5 (where C5 is the battery capacity @ 5 hour) or as
recommended by the battery manufacturers with the supporting documents subject to
the approval of DEWA. Any other de-rating factor as recommended by the battery
charger manufacturer with the supporting document shall also be considered.
Each charger shall also incorporate a boost charge feature, which shall, after having
been started, provide an automatically controlled high charge rate sufficient to restore a
fully discharged battery to the fully charged state within 8 hours and without any form
of damage to the battery. Boost charge should be controlled in such a way that
excessive gassing does not take place. The boost charge shall be initiated manually or
automatically upon detection of a significant battery discharge. An adjustable timer
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1.5.1.6.6.01-Rev.6

(D.C. SUPPLIES)

shall be provided to automatically switch the charger to the float condition after the
correct recharge period.
The diode dropper assembly shall be housed in the DC distribution panel.
Arrangement shall be made to adjust the voltage settings for both float and boost
charge modes within limits approved by the DEWA, by means of clearly marked
controls located inside the DC distribution panel.
Although it is not intended that the charger be operated with the battery disconnected,
the design of the charger shall be such that with the battery disconnected the charger
will maintain the system voltage without any damage to itself and with a ripple voltage
no greater than 2.5% r.m.s of the nominal output voltage.
The charging circuitry shall be so designed that the failure of any component will not
give a situation, which will cause permanent damage to the battery by over charging.
Each charger shall be designed with a performance on float charge such that with the
output voltage set at approximately 1.45 V per cell at 50% load and rated input voltage
and frequency, the output voltage shall not vary by more than plus 3% to minus 2%
with any combination of input supply voltage and frequency variation as stipulated in
this Specification and output current variation from 0-100% of rating.
Each charger shall be suitable for operating alone or, in parallel with the other charger.
Each charger shall have the charger on/off switch located inside the battery charger. An
emergency stop switch along with suitable protection covering shall also be provided
on the charger panel.
Each charger shall also have a taper characteristic boost charging facility which shall be
selectable by a float/boost charge selection switch and which will give boost charging
of 1.60 - 1.75 volts per cell.
Each charger shall be designed with a performance on boost charge such that with
rated input voltage and frequency, the charger output current shall be equal to 0.2 x C5
(where C5 is the battery capacity @ 5 hour) + Standing load including the design
margin and also the output voltage shall be in the range of 1.60 1.75 V per cell for a
variation of load current in the range of 0 100%.
In the event of the battery becoming discharged during an ac supply failure, the rate at
which recharging commences shall be as high as 0.2 x C5 (where C5 is the battery
capacity @ 5 hour) or as recommended by the battery manufacturers with the
supporting documents subject to the approval of DEWA consistent with maintaining
the automatic charging constant voltage feature and with the connections remaining
undisturbed as for normal service.
The charger shall have an automatic boost/quick charge feature, which shall operate
upon detection of a significant battery discharge. When after a mains failure the ac
supply voltage returns and the battery has been significantly discharged, the charger
will operate in current limit. If the current limit lasts for more than a specified time and

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(D.C. SUPPLIES)

1.5.1.6.6.01-Rev.6

the charging current does not fall back to float level, the automatic high rate charge
shall be activated.
A Lockable override selector switch shall be provided inside the charger unit to enable
a first conditioning charge to be made, in line with the battery manufacturers
recommendations, for batteries, which are shipped dry and require forming at site.
A diode assembly consisting of a minimum of two chains/strings/stages of suitablyrated diodes and contactors and the related control circuitry shall be incorporated in the
output circuit of each charger to maintain the load voltage within specified limits
during boost charging of the battery. The diode assembly shall not be in service under
normal float charging mode. Should the diode assembly fail in the boost-charging
mode, the charger shall automatically revert to the float mode. Ratings of the dropper
diodes and the contactors shall be subject to the approval of DEWA.
Each charger shall be capable of sustaining without damage to itself, a continuous
permanent short circuit across its output terminals. The use of fuses, MCBs or other
similar devices will not be acceptable in meeting this requirement.
Suitable relay shall be provided for each charger to detect failure of the incoming
supply and failure of the dc output when in float charge mode. These relays shall
operate appropriate indicating lamps on the respective charger front panel and shall
have additional voltage free contacts for operating remote and supervisory alarms.
These alarms shall be immune from normal supply fluctuations and shall not be
initiated when any one charger is taken out of service.
The charger shall also be fitted with a device to de-energize the charger in the event of a
dc output float over-voltage.
Each charger shall be provided, as a minimum, with the following instrumentation,
indication and alarm facilities: -

Indicating lamps for the ac supply to the rectifier and dc supply from the rectifier.
(Green colour to show healthiness of the system)
Indicating lamps for float and boost charging operations (amber colour).
Indication lamps for all the alarms shall be of red colour.
Voltmeter - Input voltage (Analogue type).
Voltmeter - Output voltage (Analogue type).
Ammeter - Output current (Analogue type).
Ammeter - Input current (Analogue type).
Alarm - Charger failure.
Alarm - Mains failure.
CZ meter - Battery Charge and Discharge current (Analogue type)

The following battery alarms shall also be provided:


-

Battery fuse failure


Diode assembly failure
Battery circuit faulty
Low D.C. volts
High D.C. volts
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1.5.1.6.6.01-Rev.6
-

(D.C. SUPPLIES)

Earth fault +ve


Earth fault ve
Battery electrolyte level low alarm (Other than Ultraviolet type)
Battery Isolator switch On/Off Status
Battery fuse removal

Lamp/LED test facilities shall be included.


A charger faulty alarm for each charger and a battery faulty alarm for each battery shall
be provided in the substation control room and at the SCADA Center.
In the event of providing a digital display, the alarm history (Min. 99 records) shall be
made available on the digital display board.
Mimic diagram showing the basic charger circuit along with LEDs showing status of
the switches/components shall be provided on each cubicle of the dc switchboard.
Each charger shall be equipped with a switch-fuse for the incoming ac supply and an
on load isolator for the dc output.
Tenderers shall include particulars with their tender on the method of adjustment
included to compensate for ageing rectifier elements. The construction of the charger
shall be such that access to all components is readily available for maintenance removal,
or replacement. Internal panels used for mounting equipment shall be on swing frames
to allow for access to the charger interior. All live terminals to be covered with
removable shrouding.
Each charger shall be provided with the `Name Plate containing the following
details/information as a minimum: a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
8

Manufacturer
Type
Input Supply
Input Power
Output Voltage Range
Output Current
Charging Characteristics
Float voltage setting
Boost voltage setting
Current Limit setting
Degree of Protection
Year of Manufacture
Serial No.
DEWA Contract.
QC stickers

DISTRIBUTION SWITCHBOARDS
Distribution panels shall be mounted adjacent to the charger control panel and shall be
of the cubicle type complying with the general requirements of cubicle type control
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(D.C. SUPPLIES)

1.5.1.6.6.01-Rev.6

panels. No equipment associated with the chargers shall be installed in the distribution
board.
Distribution panels shall incorporate MCBs and fuses for each of the outgoing dc
circuits and double-pole isolators for the incoming dc supplies and the components
related to dropper diode assembly. Breaker and fuse identification numbers shall be
same except for the device identification prefix viz - Q for breaker and F for fuse. The
panel shall be provided with a voltmeter and center zero ammeter of 0150% range on
each incoming circuit.
As far as power supply security is concerned, at least the following principles shall be
satisfied:
-

Normal operation: two separate in feeds via battery 1 and 2 (only incomer
breakers, say Qa and Qb closed).
One battery in feed off (under voltage): automatic changeover by closing the DC
bus coupler, say Qc, with manual restoration. In case of a major shutdown at the
station (both AC in feeds to the charger are lost), the coupling switch (Qc) shall
remain open. In case of an auto-changeover the bus coupler (Qc) shall close
before the respective incomer opens. Manually selected switching operations
shall permit momentary paralleling of the two DC systems, so as to ensure
uninterrupted power supply.
Fault on one DC bus section: the respective in feed CB to clear, however, the bus
coupler (Qc) to remain open.
Key-locked switch for auto-changeover blocking (e.g. maintenance)
Suitable voltage control shall be provided to avoid over voltages on the DC
busbar sections, each independently arranged from voltage supervision circuits
of the chargers."
Use of contactors for the dc load incomers and the bus coupler shall not be
acceptable. Instead motorized breakers shall be used for this purpose.

A battery earth fault detecting relay, which will center tap the system via a high
resistance, shall be incorporated in each of the distribution panels.
A low voltage-detecting device for the system shall be incorporated in each of the
distribution panels. No-volt relays will not be accepted for these devices. The voltage
setting shall be adjustable over an approved range.
In addition to any other requirements specified elsewhere, the battery earth fault
detecting relays and low voltage devices shall each have three alarm contacts, one for
local visual annunciation, one for the station control panel alarm indication and one for
potential free contract for external supervisory alarms. A lamp test facility shall be
provided.
Connections between the battery and the distribution cubicle shall be made in PVC
insulated cable as required. Cable laid in runs where it may be subject to damage shall
be protected by wire armoring, be sheathed overall and be cleated to walls as required.
Cable boxes or glands shall be provided as appropriate for all incoming and outgoing
circuits of the distribution switchboard and associated battery chargers. Each circuit
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1.5.1.6.6.01-Rev.6

(D.C. SUPPLIES)

shall be suitably labeled at the front of the panel and at the cable termination where the
terminals shall be additionally identified.
The bottom plate of the cubicle shall be used for cable entry only. Components like
transformers and chokes, etc. shall be mounted on the frames only.
Charging and distribution switchboards shall be provided with a copper-earthing strip
of suitable size. Calculations shall be submitted to DEWA for approval regarding the
correct sizing of the earthing strip.
The busbars, cables and incomer breakers shall be rated for calculated load and future
load. 25% spare feeders shall be considered.
The D.C. distribution board shall give alarm and indication for -

D.C. supply failure


Outgoing feeder failure

Each of the DCDBs shall be provided with the `Name Plate containing the following
details/information as a minimum: a)
b)

c)

d)
e)

Manufacturer
Busbars
Continuous current rating
Short time rating (1 min.)
Short time rating (1 sec.)
Isolator switch Rating
Continuous current rating
Short time rating (1 min.)
Short time rating (1 sec.)
Year of Manufacture
DEWA Contract

In the event of providing a separate DVR panel it shall be provided with the `Name
Plate containing the following details/information as a minimum:Manufacturer
Input Voltage
Output Voltage Range
Max. Output Current
Max. Drop Across First Stage
Max. Drop Across Total Stages
No. of VR Stages
DEWA Contract
Year of Manufacture
Serial No.
Number of feeders in Distribution board for D.C distribution is to be decided only at the
designing stage of substation. The contractor shall provide additional 25% on required
number of feeders as spare.
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1.5.1.6.6.01-Rev.6

(D.C. SUPPLIES)

ROUTINE,
WORKS
9.1

TYPE

AND

FUNCTIONAL

TESTS

AT

MANUFACTURER'S

General

The works tests shall include all routine electronic, electrical and mechanical tests when
relevant in accordance with the appropriate IEC Standard, and in addition any tests
called for by DEWA to ensure that the individual plant or equipment being supplied
meets the requirements of the Specification.
Acceptance tests during inspection by DEWA's engineer in the works of
manufacturer shall comprise all the routine tests specified for the items under
inspection on samples, which will be selected by DEWA's engineer. In addition, any of
the specified type tests may be required to be carried out in his presence, if satisfactory
evidence of carrying out such tests is not available.
9.2

Type Test and Routine Test

Battery

Battery
Charger

DC Switchboard

Type test and routine test in accordance with IEC 60623:1978

In addition the Contractor shall demonstrate that the battery


will perform the duties specified in accordance with the
approved quality plan.

Type and routine tests according to IEC 60146

In addition the Contractor shall demonstrate that the battery


charger will perform the duties specified in accordance with
the approved quality plan.

Type and routine tests according to IEC 60439.

In addition the Contractor shall demonstrate that the DC


switchboard will perform the duties specified in accordance
with the approved quality plan.

Test at Site on Equipment


All site Tests on the batteries and chargers to confirm charger ratings and adjustment,
the battery and charger alarm system and battery capacity shall be carried out by the
manufacturer of each equipment. Prior to start testing and commissioning of the dc
system, the contractor shall furnish all the relevant testing & commissioning
procedures, and technical manuals, approved test formats and the factory test reports,
etc.
In case a microprocessor controlled battery charger is supplied, the contractor shall
provide necessary software, donggle, cables and the PC/laptop. Necessary
demonstration and training shall also be arranged for the maintenance staff of DEWA
The open circuit cell voltages of the batteries when fully charged shall be recorded.
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1.5.1.6.6.01-Rev.6

(D.C. SUPPLIES)

The insulation to earth of the complete dc installation shall be tested.


A list of setting parameters along with details of the input, output voltage, current
and wattage shall be made available/pasted in a suitable manner on the back of front
door of the charger.
10

LIST OF STANDARDS
IEC 60623

Vented nickel cadmium prismatic rechargeable single cells.

BS 5634

Testing potassium hydroxide used in alkaline cells.

BS 381C

Specification for colours for identification coding and special purposes.

BS 4417

Specification for semiconductor rectifier equipments.

BS 88

Cartridge fuses for voltages up to and including 1000 V AC and 500 V


DC.

IEC 60146

Semiconductors converters.

IEC 60439

DC Switch Boards

IEC 60410

Selection Criteria for sample collection from different cell lots.

IEEE Standard 1115-1992 Recommended Practice for Sizing Nickel-Cadmium Batteries


for Stationary Applications.
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