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48 VOLT AND 125 VOLT

FLOODED LEAD-ACID BATTERIES


USED IN ELECTRICAL SUBSTATIONS

1. SCOPE

1.1 This specification covers the physical and electrical requirements for flooded, vented,
lead-acid, stationary batteries and racks, having ratings and accessories as detailed in
this document.

1.2 The vendor shall manufacture, test, package, and deliver the batteries described herein
with the required documentation to SRP’s specified warehouse location.

2. APPLICABLE STANDARDS

2.1 Except as modified by this specification; the batteries and battery racks shall be
designed, manufactured, and tested in accordance with the applicable requirements of
the latest ANSI, IEEE, NEMA, and UL standards.

2.2 The following specific standards shall apply except as modified herein:
2.2.1 IEEE-450, Recommended Practice for Maintenance, Testing and Replacement
of Large Lead Storage Batteries for Generating Stations and Substations
2.2.2 IEEE-484, Recommended Practice for Installation Design and Installation of
Vented Lead-Acid Batteries for Stationary Applications
2.2.3 IEEE-693, Recommended Practices for Seismic Design of Substations
2.2.4 IEEE-1578, Recommended Practice for Stationary Battery Electrolyte Spill
Containment and Management

3. SERVICE CONDITIONS

Typical service conditions are as follows:


3.1 Flooded battery installations are typically located inside a ventilated, climate controlled
control houses with dedicated battery rooms.

3.2 Temperature in battery installation areas is controlled within the following range: 80°F
maximum ambient, 65°F minimum ambient and 75°F average 24 hour ambient.
3.3 Relative humidity in battery installation areas is: 50% maximum ambient, 5% minimum
ambient, and 30% average 24 hour relative humidity.
3.4 Seismology: Battery installation racks specified herein shall be designed to conform to
IEEE Practices for Seismic Design of Substations, IEEE Standard 693. The seismic
design shall be per Annex J. The seismic level shall be classified as ‘Low Level’.
3.5 Altitude (feet above sea level): Less than 3,000 feet above sea level.

EXTENSIVE REVISIONS Page 1 of 8


Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc


4. MANUFACTURER'S QUALIFICATIONS
4.1 Approved manufacturers shall have on file, with the Electric System Planning &
Engineering Department of Salt River Project (SRP) or shall submit with their bid, their
latest qualification test reports in accordance with the latest edition of the applicable
standards listed in Section 2.2 of this specification and as listed below:
4.1.1 8 hour capacity test report
4.1.2 Seismic qualification report

4.2 Any manufacturer who has not previously provided batteries and battery racks under
this specification or who proposes to furnish batteries and racks differing from that
supplied on previous orders shall submit copies of test reports in accordance with the
latest edition of the applicable standards listed in Section 2.2 of this specification and as
listed below:
4.2.1 8 hour capacity test report
4.2.2 Seismic qualification report

4.3 Manufacturers shall employ a documented, on-going process, of quality control and
continuous quality improvement, approved by SRP, to ensure the quality of incoming
materials and monitor the manufacturing process. Evidence of the quality assurance
program shall be submitted with the bid for SRP’s evaluation.

5. BATTERY DESIGN AND CONSTRUCTION REQUIREMENTS


5.1 General Design Requirements
5.1.1 Battery shall be designed for switchgear control applications and shall be
capable of meeting the performance ratings in Section 6, regardless of the amp-
hour rating as stated in this specification. Amp-hour ratings stated in this
specification are presented for item differentiation purposes only.
5.1.2 Battery shall have a design life of at least 20 years, assuming a maximum of 150
deep discharge cycles over the entire service life
5.1.3 Battery shall be comprised of a single series string. Parallel strings shall not be
allowed for the standard material sizes given in Section 6.
5.1.4 Each cell or jar shall contain a permanent label that indicates the battery type,
model, nominal Amp-Hour capacity at the 8 hour rate to 1.75vpc at 77 deg. F,
recommended float voltage, and nominal specific gravity. In addition, each cell
or jar shall be permanently marked with the Date Of Manufacture and specific
identification number of the cell.
5.1.5 The battery shall be equipped with catalyst recombination caps or other Engineer
approved method of gas recombination for minimizing venting/water loss. All
batteries purchased under this specification shall be so equipped or they will not
be considered.

EXTENSIVE REVISIONS Page 2 of 8


Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc


5.1.6 The battery shall be designed to withstand a short circuit across the output
terminals for one minute without a failure of the jar, jar top, or post seals.
Manufacturer shall clearly state the short circuit rating of each battery size
supplied according to this specification.
5.1.7 The maximum weight of any single-cell jar shall not be more than 100 pounds.
75 pounds maximum weight per single-cell jar is preferred. The maximum
weight of any multi-cell jar shall not be more than 150 pounds.

5.2 Cell Design Requirements


5.2.1 Cell jars shall be constructed of one-piece molded high impact transparent
thermoplastic, with all walls of equal thickness and strength, with a mechanically
sealed top cover. Styrene-Acrylonitrile thermoplastic jars are preferred.
5.2.2 Cell jar tops shall be constructed of flame retardant material which can pass the
requirements in UL94-V0 and have an oxygen index of 28% or higher.
5.2.3 Cell jars shall be transparent to allow for visual inspection of plates, plate
separators, and electrolyte level. Cell jar shall have maximum and minimum
electrolyte level marks clearly visible from 2 sides of the jar.
5.2.4 Cell jars shall allow sufficient space for cell growth and sloughed material at the
bottom of the jar to prevent bridging.
5.2.5 Positive electrodes shall be constructed with a tubular grid design with a gauntlet
tube surrounding the positive grid. (OPzS type) Positive flat plate designs will
not be accepted for substation applications.
5.2.6 Battery plates shall be constructed from Lead-Calcium alloy. All lead alloys shall
have less than 2% Antimony content. Lead-Selenium alloys are also acceptable.
5.2.7 The electrolyte shall be an aqueous solution of sulfuric acid in water with a
nominal specific gravity of 1.240.
5.2.8 There shall be an ample reserve of electrolyte in the cell to minimize
maintenance.

6. BATTERY PERFORMANCE RATING


6.1 All batteries shall have capacities rated in Amp-Hours at 77°F (25° C) at the 8-hour
discharge rate to an end voltage of 1.75 VPC.
6.2 Batteries shall deliver a minimum of 90% of nameplate amp-hour capacity when
commissioned according to manufacturer’s instructions, and tested according to IEEE
standards at time of installation, and deliver 100% of nameplate amp-hours after three
months of float charging.

EXTENSIVE REVISIONS Page 3 of 8


Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc


6.3 Batteries supplied under this specification shall consist of the following sizes and
ratings:
Flooded-Vented Battery - Standard Material Sizes
SRP Battery String Number of Jars Amp-Hour
1
Stock Code Nominal Voltage per String Rating
5077768 48 4 or 8 150
5077756 48 24 250
5077749 48 24 350
5077750 48 24 450
5077775 48 24 650

5077757 125 60 250


5077758 125 60 350
5077751 125 60 450
5077752 125 60 650
Note1 - Nominal Amp-Hour rating is based on an 8Hr discharge rate to 1.75VPC @ 77°F (25°C)

7. ACCESSORIES
7.1 The battery shall be supplied complete with the following: All necessary inter-cell
connecting links with holes properly drilled for ease of assembly, catalyst/gas re-
combiner caps for each cell, O-rings and gaskets as required.
7.2 All hardware fasteners shall be either metric or SAE size. Batteries and racks supplied
with mixed hardware sizes are not acceptable and shall be returned. Manufacturer shall
state in its proposal whether it will supply metric or SAE hardware for both the battery
and the rack.
7.3 The following spare parts shall be provided with EACH battery bank:
(1) Set of Cell Numbers
(2) Spare Insulated Post Covers
(1) Spare Catalyst Vent Caps
(2) Spare Inter-cell Connectors
(2) Spare Battery Terminal Screws
(2) Spare Wave Washers
(2) Spare Terminal Lugs

7.4 A copy of the manufacturer recommended battery installation procedures, owner’s


manual, applicable MSDS, and assembly drawings shall be included with every battery
and rack.
EXTENSIVE REVISIONS Page 4 of 8
Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc


7.5 The accessories and spare parts for each battery shall be clearly labeled, packaged
separately, and be shipped together with the battery as required by the packaging and
shipping requirements of this specification.
7.6 Battery price provided shall include the cost of the accessories listed in herein.

8. BATTERY RACK

8.1 Battery rack(s) shall be either a 2-step, a 2-tier, or a 2-step & 2-tier design and shall
conform to the IEEE standards listed in section 2. The rack shall be designed with front
and back rails so that batteries will not become dislodged if the rack is bumped. All 2-
tiered racks shall have bracing, similar to a light duty seismic rack design.

8.2 Battery rack(s) shall be of steel construction and shall be painted or powder coated with
acid resistant epoxy not less than 3 mills thick. Racks are to include plastic channel rail
insulation, steel angle support frames, sway braces and all necessary hardware.

8.3 Battery rack(s) for flooded cells shall be constructed so as to allow access for viewing
electrolyte level of all cells from one side and for testing and maintenance while all cells
are in place. Racks shall be designed for cell installation such that edges of plates are
visible from the front.

8.4 Two-tiered battery racks shall be designed with sufficient height to accommodate the
installation and operation of a catalyst recombination cap, and allow for cell removal
from the lower tier without tipping the cell, and without disassembly of the rack.

8.5 Vendor shall provide with the rack the correct length cables appropriate for
interconnecting battery rows and tiers within the rack. Connecting cables between rows
and tiers shall be insulated 3/0 AWG copper welding cable, at a minimum.

8.6 Battery rack(s) for 48 volt battery shall conform to the following total maximum combined
space limitations: 7 feet long, 2 1/2 feet wide, and 5 feet high, or as specified.

8.7 Battery rack(s) for 125 volt battery shall conform to the following maximum total
combined space limitations: 12 feet long, 2 1/2 feet wide and 5 feet high, or as
specified.

8.8 Battery racks and spill containment system shall be quoted and ordered as a separate
line item from the battery when a rack and spill containment system is specified.

8.9 Battery rack(s) shall be packaged individually, be clearly labeled, and shipped as
required by the packaging and shipping requirements of this specification. Each rack
shall come with complete, intelligible, assembly drawings.

EXTENSIVE REVISIONS Page 5 of 8


Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc


8.10 All equipment specified herein shall be designed to conform to IEEE Standard 693 -Annex
J. The seismic qualification level for Arizona shall be considered ‘Low Level’.
8.11 A spill containment system per IEEE-1578 shall be quoted with every flooded battery rack.
The spill containment system shall include a free-standing tray with electrolyte absorbing
and neutralizing agents. The spill containment system shall be classified as non-
flammable and shall be NFPA and UL-94 compliant.
8.12 This specification applies to the following SRP standard material racks for flooded-vented
lead-acid batteries:
Racks for Flooded-Vented Batteries - Standard Material Sizes
Battery String Size Number of Jars Battery Rack Configuration
Voltage Capacity per String 2-Step 2-Tier 2-Step/2-Tier
150 4 or 8 NA
250 24
48 350 24
450 24
650 24
250 60
350 60
125
450 60
650 60

9. PACKING AND SHIPPING

9.1 All materials and articles shall be prepared for shipment in such manner as to protect
them from damage and allow for easy sorting of the packages upon arrival. Equipment
damaged in transit shall not be accepted and shall be returned.

9.2 All packages shall clearly display the SRP Purchase Order #, and Item # from the PO on
the outside of the packaging. Each group of packages, consisting of battery, rack, and
accessories, shall be clearly labeled so that upon receipt, the different groups can be
readily sorted and assembled.

9.3 All packages containing batteries shall be strapped to a new forklift pallet and secured in
all three axis (X,Y,& Z) with non-metallic pallet straps.

9.4 Each battery shall be packaged separately. Heavy corrugated cardboard or foam or
other shock absorbing material shall be placed between the battery and the pallet, and
between each cell or jar.

9.5 One set of accessories shall be packaged separately and shipped with each battery.
When a battery rack is specified it shall be packaged separately and shipped with each
EXTENSIVE REVISIONS Page 6 of 8
Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc


battery.

9.6 Each battery and rack shall be shipped complete. Partial shipments and/or short
shipments shall not be accepted.

9.7 Batteries requested under terms of a contract shall be prepared and shipped within two
weeks of receipt of a release to ship notification from SRP.

9.8 All bidders shall submit examples of their packaging (either drawings or photographs) to
demonstrate compliance with the above requirements as part of their proposal. Failure
to comply with the packaging and shipping provisions of this specification shall
constitute grounds for cancelation of the purchase contract.

10. WARRANTIES
10.1 Battery and rack(s) shall be warranted free from defects for 5 years from the date of
shipment. Defective cells and components shall be replaced free of charge within this
time.
10.2 Battery post sealing system and jar top shall be warranted free from defects, cracking,
or electrolyte leaks for a period of 10 years from date of manufacturer.
10.3 Battery shall be designed and warranted to deliver 80% of rated capacity for 20 years
for flooded-vented batteries from the date of shipment from the factory. The vendor
must provide a prorated adjustment to the warranty based on remaining service life
toward the purchase of another battery. A copy of the manufacturer’s warranty shall be
submitted with the bidder’s proposal. Alternate warranty provisions may be considered.

11. RECYCLING
All components of the batteries provided under this specification shall be recyclable using
standard recycling equipment and techniques. This includes the lead, acid, and plastic
components. Documentation verifying the recyclability of all battery components shall be supplied
on all proposals.

EXTENSIVE REVISIONS Page 7 of 8


Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc


12. REQUIRED TECHNICAL DATA

12.1 The following information shall be supplied with each bid proposal:
12.1.1 Jar or block dimensions in inches
12.1.2 Weight per jar in pounds
12.1.3 Number of jars per step and/or tier on a rack
12.1.4 Fully dimensioned rack drawings with dimensions in inches
12.1.5 Weight of each battery rack (fully loaded) in pounds
12.1.6 List of accessories and spare parts to be provided
12.1.7 Cell jar material and oxygen rating
12.1.8 Documentation describing the catalyst recombination cap
12.1.9 Documentation describing the spill containment system
12.1.10 Quality assurance program details
12.1.11 Battery recyclability documentation
12.1.12 Warranty documentation for battery and rack

12.2 Drawings in AutoCAD or Microstation format shall be supplied which shall include
projected floor space, overall height, terminal pad heights, foundation requirements,
center of gravity, assembly, and anchor bolt drawings. The vendor shall submit this
information within 30 days after a receipt of order.

12.3 Certified test reports (design life and performance tests for the type and size of cell)
showing that the batteries to be supplied can meet or exceed the performance ratings
published by the manufacturer. The vendor shall submit certified test reports within 30
days after a receipt of order.

12.5 Required documentation shall be submitted to:

US Postal Service Courier


Document Coordinator Document Coordinator
Mail Station XCT317 Mail Station XCT317
Salt River Project OR Salt River Project
P. O. Box 52025 2727 East Washington St.
Phoenix, AZ 85072-2025 Phoenix, AZ 85034-1403

EXTENSIVE REVISIONS Page 8 of 8


Standard Material SUBSTATION MATERIAL ISSUE DATE: 08-03-92
Specifications
48 VOLT & 125 VOLT REV. DATE: 10-23-14
FLOODED LEAD-ACID BATTERIES
USED IN ELECTRICAL SUBSTATIONS APPROVAL: T.A. Keels

PROPRIETARY MATERIAL SM-260010 – 30 (5016215 – 5075340) SM-260010.doc