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GENERAL :

TECHNICAL SPECIFICATION FOR PLCC BATTERY

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 Acid Battery sets shall be of best class and capable of satisfactory operation on tropics with humid atmospheric condition without distortion (or) deterioration. The workmanship shall be of highest grade and the entire works in accordance with the best modern practice. I. TECHNICAL SPECIFICATIONS:i) Type ii) Positive Plates iii) Negative Plates iv) Connector v) Initial charging vi) Accessories : : : : Lead-Acid : Tubular plates Pasted plates : Lead plated copper connector and Lead plated Brass nuts, bolts and washers. Conforming to IS:1651/1991 Teak wood stand, cell stand insulators, cell number plates. 2 Nos. Syringe Hydrometers, Battery Thermometer and 3V-0-3V cell testing voltmeter shall be supplied in the accessories with battery set. It may be noted that the voltmeter shall be of accuracy class not inferior to 0.5 and the resistance shall be atleast 1000 Ohms per Volt. The Thermometer shall be for measuring appropriate temperature and one division of the graduated scale shall represent at the most1 Degree "C". The accuracy of calibration shall be not less than 0.5 Degree "C".The Hydrometer shall be provided with graduated scale one division of which shall represent at the most 0.005 unit of Specific Gravity. The accuracy and calibration shall not be less than 0.005 unit of Sp. Gravity.

vii) Capacity

The capacity of the Batteries are at 10Hrs discharge rate to an end voltage of 1.85V per Cell. The batteries are assembled with tubular positive, pasted negative plates and microporous PVC separators in wrapped hard rubber containers complete with acid level

viii) Insulation

indicating floats, connectors, Bolts, nuts and washers as per IS 1651/1991. The battery sets shall be supplied with battery stands made out of seasoned Teakwood, stand insulators, cell insulaltors and Inter-row cell connectors, in dry uncharged condition and acid for filling in separate containers (with 10% excess) as per IS 1651/1991. The internal insulation of the cell shall be such as to stand the heavy wear & tear. The separators shall not split (or) crush under heavy strain (or) discharge. Batteries with individual cells connectors in series Connectors by welding, soldering will not be accepted. The connectors should be such as to facilitate easy isolation of any cell, when necessary, for purpose of maintenance and shall be made of lead. Copper connectors suitably coated with lead to withstand corrosion due to sulphuric acid shall be used where the cells are called upon to discharge at very high rates. Bolts, nuts and washers for connecting the cells with intercell connectors shall be robust, made of brass material and effectively coated with lead to prevent corrosion. The stand shall be for single tier two row cell arrangement for all the battery sets. The stand shall be made of seasoned teakwood and shall be supplied well finished but without painting. However, in order to apply three coats of anti-corrosive black paint subsequently sufficient quantity of anti-corrosive black paint in separate containers shall be supplied with each stand. TNEB will arrange to paint the stands made of Teakwood. The drawing of the wooden stand may be furnished. If any change in the dimensions of the wooden stand is required, the same has to be incorporated to meet the requirements. 10% excess electrolyte in carboys for initial charging. The specific gravity of electrolyte supplied for the initial charging of the batteries shall be uniform and such as to obtain the required value i.e. 1.200 (or) as per specification of the manufacturer, equally in all the cells after the completion of the first charge itself. It shall not necessitate adding concentrated acid for obtaining required specific gravity later. The containers shall be of moulded (or) wrapped Hard rubber and shall conform to IS 1146/1981. The Type Tests for containers conforming to the requirements

ix) Terminals and

x) Wooden Stand

xi) Electrolyte:

xii) Cell containers:

as per IS 1146/1981 may be furnished. The containers shall be designed such that they do not crack (or) become leaky and shall withstand normal conditions of service and will resist any acid action on them. The Technical particulars are specified in Annexure.

PART - I TECHNICAL GENERAL 1.0 TEST CERTIFICATE :

1.1

Test Certificates in triplicate for the materials furnishing the results of the tests as per latest issue of ISS shall be forwarded and got approved before the materials are despatched. In addition to the tests called for in the specification the purchaser reserves the right of having such tests as he desires carried out at his own expenses to satisfy himself that the materials conform to the requirements of this specification. The materials may be rejected if the test results are not satisfactory. The type test certificates (photostat copies) as per latest ISS shall be furnished with the tender for reference and date of type test shall not be later than 5-years period. (Refer inspection clause 8 also for the details of inspection/ tests.) ROYALTIES AND PATENTS : All Royalties for patents or the charges for the use or infringements thereof that may be involved in the contract shall be included in the tender prices. The tenderer shall protect the purchaser against any claim thereof. GUARANTEED PARTICULARS: The tenderer shall furnish all the particulars of the materials offered against this specification. Unless full details are furnished, the tender may not be considered. DEPARTURE FROM SPECIFICATION: 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 this specification. Unless this is done, the materials offered shall be considered to comply in every respect with the terms and conditions of this specification. RESPONSIBILITY: The tenderer is responsible for safe delivery of the materials at the destination stores. The tenderer should also include and provide for security, protecting and packing the materials so as to avoid damages or loss in transit. PACKING : The packing may be in accordance with the manufacturer's standard practice. The contractor should however ensure that the packing is such that the materials reach their destination without damages after transport by Rail or Road. MAXIMUM WEIGHTS AND DIMENSIONS OF PACKINGS: The contractor is responsible for informing himself of the facilities that exist for road and rail transport to site, the maximum packages which can be conveyed by the Railway and crane lift available at the destination

2.0 2.1

3.0 3.1

4.0 4.1

5.0 5.1

6.0 6.1

7.0 7.1

railway station. The contractor is also responsible for any loss or damage during transport. 7.2 Each case or package should be clearly marked and should detailed packing list. contain

8.0 8.1

INSPECTION : The accredited representatives, of the purchaser shall have access to the contractor's works at any time during working hours, for the purpose of inspecting the manufacture of the materials and for testing the selected samples from the materials covered by this specification. The contractor or the sub-contractor shall provide facilities for testing such samples as per standards agreed between the supplier and the purchaser. The tenderer shall specify the international standards which are applicable for the equipments to be quoted under this specification. The purchaser reserves the right to conduct any other reasonable tests at manufacturer's premises or at site. The purchaser shall be supplied with 2 copies of test result. A separate copy of type and routine tests to be carried out on the equipments shall be enclosed with the Tender. Tenderers are requested to furnish in their tenders the exact location of their factory with address to enable inspection by Board if considered necessary. It should be supplier's responsibility to arrange for inspection, despatch etc., in time to keep up the delivery schedule. A reasonable time of atleast 15-days shall be given to the Board for arranging inspection. QUALITY PLAN : You will prepare, submit and discuss with us, and based on such discussions finalise within 30 days (thirty days) from the date of the letter of intent detailed quality plans in the format as given in Schedules for all components of the equipments manufactured by you setting out during the various stages of manufacture the quality practices and procedures to be followed by your quality control organisation, the relevant reference documents/standards/ acceptance level, inspection documentation raised etc. In these quality plans we will identify "Hold Points" beyond which work will not progress without our consent in writing. For the components/equipments procured by you for the purpose of this contract your purchase specifications and enquiries shall call for such quality plan of the successful vendor which shall be discussed and finalised by you, in association with us, in the aforesaid manner and the same shall form part of your purchase order on your sub vendor. We also reserve our right to carryout quality audit and quality surveillance of the system and procedures of your/your vendor's quality management and control

8.2 8.3

8.4

8.5

9.0 9.1

activities. However, such audit/ surveillance by us shall not relieve you of any 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 the complete technical details of the equipments. Information regarding the country of manufacture or origin of materials used in the manufacture of the articles should be furnished. The tenderer should include all minor accessories even though not specifically mentioned in this specification but which are essential for the completeness of the materials ordered and which are required for efficient operation for the equipment ordered. The tenderer shall not be eligible for any extra charges 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 interchangeable with each other. QUANTITIES : 12.1 The quantities mentioned in this specification are only approximate. The purchaser reserves the right to revise the quantities at the time of placing 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 advance intimation regarding despatch to be sent will be intimated by the consignees in the despatch instructions. 14.0 CLIMATE CONDITIONS : 14.1 The materials are for use in Tamil Nadu and the materials should satisfactory for operation under tropical conditions in Tamil Nadu. 1. 2. 3. 4. 5. 6. 7. be

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

8.

9.

The climatic conditions are prone to wide variations in ambient conditions and equipments offered under this specification shall be suitable for installation at the Sub-station Control Rooms, Carrier Rooms & Power Houses as detailed elsewhere in this specification. All electrical devices shall be given tropical and fungicidal treatment, for smoke and mild acids are also present in the atmosphere.

15.0

ELECTRICITY RULES :

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

16.0 EQUIPMENTS/MATERIALS AND WORKMANSHIP : 16.1 All the equipments shall be of the best class and capable of satisfactory operation in the tropics with humid atmospheric conditions without distortion or deterioration. Unless otherwise specified the equipment shall conform to the requirements of the appropriate Indian or I.E.C. or other national Standards. Where a specification covering the equipments in question has not been published, the tenderer should specify to 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 in accordance with the best modern practice. The whole of the work shall be of the highest class throughout well finished and of approved make. The entire design and construction shall be capable of withstanding the severest stresses likely to occur in actual service and of resisting rough handling during transport. &&&&

ANNEXURE TECHNICAL PARTICULARS. LEAD-ACID STATIONARY BATTERIES IS1651/1991 ------------------------------------------------------------------------------------------------------------Sl. Description 48V/120 AH 48V/250 AH 48V/400AHNo.--------------------------------------------------------------------------------------------------1. Make & Type :

2. 3. 4. 5.

Capacity Number of cells in Battery set Discharge capacity at 3 Hrs. Rate for end volt 1.8 volt. Discharge capacity at 10 Hours Rate for end voltage 1.85 volt Normal charging rate Maximum charging rate Normal charging time after complete discharge Recommended current For initial charging Time required for initial charging at the above current Watt-Hour efficiency when discharged at 10 Hours rate Number of rows used for the stand :

120AH AT 10 HRS. 24 NOS. 86AH 120AH

250AH AT 10 HRS. 24 NOS. 179.25AH 250AH

400AH AT 10 HRS. 24 NOS. 287AH 400AH

6. 7. 8. 9. 10. 11. 12.

: :

6A 15 A 24A 12 A 30 A 48A 12-14 HRS. 12-14 HRS. 12-14 HRS. 6 Amps. 100 Hrs. 75% 15 Amps. 100 Hrs. 75% Double row 24Amps. 100 Hrs. 75% Double row

Double row

------------------------------------------------------------------------------------------------------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)

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Approximate weight of 0.525Kg.Antimony per cell Type & Material of separators

: :

0.175Kg.

0.325Kg.

PVC Envelope PVC Envelope PVC Envelope

Material of containers : Hard Rubber Hard Rubber Hard Rubber 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 cell for first filling at 27 Deg.C at 27 Deg.C at 27 Deg.C Recommended specific gravity : 1.200 1.200 1.200 at the end of a full charge Expected specific gravity at : 1.095 1.095 1.095 the end of the discharge at the specified rate ( 0.015%) Recommended trickle charging 120-480mA 250-1000mA 400-1600 mA rate for different type of working Overall dimensions of each : As per IS 1651 cell and complete battery set. Distance between centres of : cells when erected. Weight of cell complete with : Acid. Recommended Maximum period : 2 Year of storage (dry uncharged) Internal resistance of cell : 1.60 m As per IS 1651 As per IS 1651 2 Year 0.795 m 2 Year 0.535 m

------------------------------------------------------------------------------------------------------Sl. Description 48V/120 AH 48V/250 AH 48V/400AHNo. ------------------------------------------------------------------------------------------------------Testing Equipments: 1. Voltmeter: a) accuracy class 0.5 b) resistance per volt 1000 Ohms per volt 2. Hydrometer: a) graduations reading possible. Min. 0.005 3)Thermometer: a) Range: 0 to 100 Deg.C b) Graduation: 1 Deg.C Min. temperature possible

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