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BATTERY AND BATTERY CHARGER TECHNICAL SPECIFICATIONS Clause No. Particulars 1.0 SCOPE 2.0 TYPE, RATING AND DESIGNATION CELLS 3.0 MATERIALS FOR CELLS 4.0 CONSTRUCTIONAL REQUIRMENTS AND DESIGN CRITERIA FOR BATTERIES 5.0 ACCESSORIES 6.0 END CELL TAPPING TECHNICAL SPECIFICATIONS FOR BATTERY FOR 110 KV, 66 KV, 33 KV SUB-STATION 1.00 SCOPE : This specification covers supply, erection and commissioning of the Battery Sets at the specified stations. 2.00 TYPE, RATING AND DESIGNATION OF CELLS: 2.01 TYPE : Lead Acid stationary cells Tubular positive plate type. 2.02 RATING : Battery & Charger Page 1 of 37
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Phani Kumar

The General Technical Particulars of Battery Charger and Battery
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Page 1: Battery

BATTERY AND BATTERY CHARGER

TECHNICAL SPECIFICATIONS

Clause No. Particulars

1.0 SCOPE

2.0 TYPE, RATING AND DESIGNATION CELLS

3.0 MATERIALS FOR CELLS

4.0 CONSTRUCTIONAL REQUIRMENTS AND

DESIGN CRITERIA FOR BATTERIES

5.0 ACCESSORIES

6.0 END CELL TAPPING

TECHNICAL SPECIFICATIONS FOR BATTERY FOR 110 KV, 66 KV, 33 KV SUB-STATION

1.00 SCOPE :

This specification covers supply, erection and commissioning of the Battery Sets at the specified stations.

2.00 TYPE, RATING AND DESIGNATION OF CELLS:

2.01 TYPE :Lead Acid stationary cells Tubular positive plate type.

2.02 RATING :

i) 100 AH FOR 110 V BATTERIES.

2.03 DESIGNATION :

i) 100AH FOR 110 V BATTERIES.

2.04 DISCHARGE RATE :

Ampere hour rating specified as above over a 10 hour discharge rate.

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2.05 NOMINAL VOLTAGE RATING OF EACH CELL :

2.0 Volts

3.00 MATERIALS FOR CELLS :

Generally in accordance with clause (4) and sub-Clause thereof as per rs : 1651.

4.00 CONSTRUCTIONAL REQUIRMENTS AND DESIGN CRITERIA FOR BATTERIES :4.01 Generally in accordance with clause (5) and sub-clause thereof as per IS : 1651.

4.02 The Batteries shall be suitable for being installed indoors in a separate Battery Room in a hot, humid and tropical atmosphere. The contractor shall provide the Battery Room and Exhaust fan.

4.03 The Batteries shall be lead acid type tubular positive plates type heavy durable half pasted type negative plates, confirming to IS:1651 latest version. The positive plates shall resist the “Foaming Action” of the current during charge and discharge and retain it’s strength, rigidity, shape and dimensions over the operating life of the plates.

4.04 a) The cells shall be mounted on wooden stands/racks in a two tier formation on Battery Insulator supports Each cell container shall be mounted on the wooden racks with 4 Nos. of corner insulator supports. The insulator supports shall be made of white glazed porcelain. The wooden stand shall be treated and painted with anticorrosive acid resistant black paint. The quality and durability of the wood and the paint shall be such as not to deteriorate during the entire life span of the Battery. The wood or paint shall not corrode due to chemical reaction caused by acid spills. The spacing between 2 tiers shall be so as to permit taking of readings by a hydrometer in vertical position.

b) Cell inter connectors shall be of lead or lead coated copper flats or rods. Bolts and Nuts to be provided at the cell terminal posts shall also be lead coated. Thickness of lead coating shall conform to clause 5.5 of IS : 1651-1979. Interior inter connections shall be insulated Lead Rods or Lead coated copper flats or rods.

4.05 The Battery shall be sized to meet an Emergency Duty cycle of about 80 Amps. Continuously for about an hour or so from a healthy fully charged Battery when the charger is in-operation or out of services.

4.06 The design of the cell shall be such that when they are fully charged they should be capable of receiving a trickle charge or an equalizing charge if necessary without excessive gassing of causing an abnormal rise in the temperature of the electrolyte. The supplier shall furnish the recommended interval at which equalizing charge are to be applied.

4.07 a) The plates shall be high corrosion resistant with low electrical resistance and high mechanical strength. The oxides in the negative grid plate shall be mixed with Chemical Additives and Expanders to aid their longevity.

b) The Polarity of the Terminals shall be marked for identification. The positive terminal may be identified by ‘P’ or a (+) ve sign or Red color and negative terminal may be identified by ‘N’ or a (-) ve or Blue color mark. Marking shall be permanent and non-deteriorating.

4.08 Each cell shall be provided with an identification number plate. The Number plate shall be an enameled plate with red or Black numbers on white background. The number plates shall be capable of being screwed to the wooded stand below each cell.

5.01 CONTAINERS :

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The Batteries shall be supplied with open type glass containers or hard rubber containers. The containers shall conform to relevant standards.In case the Battery offered conforms to standards other than IS : 1651, a copy of the relevant standard shall be enclosed to the tender.

4.10 LUGS :The Lugs shall be of plate type and shall have the form conforming to Indian/International standards. The Lugs of like polarity shall be connected by lead Bolts. The type of connection adopted shall be clearly indicated in the Tender.

1) SEPERATOR :

The Separator shall be of wood, glass or other acid resisting materials. They shall confirm to relevant IS of International standards.

4.12 HYDRO METERS :Hydro meter suitable for loading in any cell on the Battery and with a reasonably long scale permissible for the depth of the cell and capable reading specific gravity 1.100 to 1.300 with sub-divisions 0.022 Shall be provided. A wall mounting type Teak holder for the Hydrometer shall also be supplied.

4.13 ELECTROLYTE :Each cell shall be supplied uncharged and without an Electrolyte. The full quantity of electrolyte require for the first filling with 10% extra shall be included in the offer. The electrolyte shall be supplied in non-returnable acid resisting jars. The Electrolyte shall generally conform to IS : 260 or equivalent international standard .

a) ACCESSORIES :The following Battery accessories shall also be supplied :

Qty. per station.

a) Cell testing voltmeter (Range 3-0-3) 1 No.b) Rubber Apron 2 Nos.c) Rubber shoes (Knee height) 2 Pairs.d) Thermometer (mercury/Alcohol type)

0 to 100 deg. C. 1 No.e) Glass funnels 2 Nos.f) Spanners 1 Set.g) Acid resisting jars 4 pints capacity. 2 Nos.h) Rubber Gloves 2 Pairs.i) Pipette 1 No.j) Bridging clamps for cutting out individual cell in event of defect k) Protective goggles, Battery log books, tool box.

6.00 END CELL TAPPING :The Vendor shall clarify as to whether it is preferable to have end cell tapping arrangement in the Battery Banks in order to control the voltage of the load side when the side when the battery is being boost charged. If the End cell Tapping is recommended to regulate the voltage across load and Battery set, supplier shall agree to supply necessary switch to in/out the cells, as also End cells as loose items.

7.00 DRAWING :Vendor shall supply a full dimensioned drawing of completely assembled cell and stillage and literature along with the tender for each type of Battery Set specified. Successful Vendor shall

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supply six sets to the consignee and 12 sets to the officers designated in the purchase order fully detailed dimensioned drawing of complete assembly. Characteristic curves and instruction manuals required for erection charging and satisfactory operation and maintenance of the batteries under service condition. Further, one set of reproducible originals of all the approved drawings shall be supplied.

BATTERY CHARGER

TECHNICAL SPECIFICATIONS FOR 110 V BATTERY CHARGERS Battery Charger (i) 110V, 60 AH (ii) 110V, 100 AH

1.00 Intent of Specifications :

1.01 This specification is intended to cover the design, manufacture, testing at works and supply of Battery charger equipments complete with all materials and accessories for efficient and trouble free operation.

1.02 The scope of the work shall also include, at the option of the purchaser, supervision of erection, testing, commissioning and putting into commercial operation of the equipment mentioned in the specification.

2.00 Scope of Work :

2.01 Scope of Supply :

2.11 Type and rating of the equipment are detailed below :

Sl. No. Particulars1 Related Voltage 110 V DC2 Rated Ampere Hours 60 AH 100 AH 3 Boost charging current

2 Finishing current 3 Maximum current

b) A10 A

7 A15 A

4 Truckle charge current 2 Finishing current b) Maximum current

30 mA120 mA

50 mA20 mA

5 Continuous Load in Amps. 5A 5A6 Voltage Variation

Float charge conditionBoost charge conditionAcross load

110 – 120 V102 – 145 V

110 V7 Ripple content – To be limited to less than 2%

2.12 Each battery charger shall be furnished complete with accessories as listed in the annexure.

2.13 One set of special tools for each sub-station. Any relevant drawings, date and instruction manuals.

3.03 Scope of Service :

3.04 The services of an engineer experienced in erection and commissioning of the equipment of similar type and rating on per diem basis. The work includes but not limited to :

3.05 Complete checking of the materials at site and advising the purchaser of any discrepancy thereof.

3.06 Advice on procedure of erection to be followed.

3.07 Regular supervision and following up of erection work done by other.

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3.08 Testing, Commissioning and putting the equipment into successful commercial operation.

1.01 Exclusion from scope of work :

1.02 All concrete foundation works.

1.03 Labour and equipment for unloading and installation.

1.04 Power and control cables for connection with equipment supplied by others.

3.0 General requirements :

3.01 Codes and Standards :

All equipments and materials shall be manufactures and tested in accordance with the latest applicable standards.

3.02 Completeness of Supply:It is not the intent to specify completely herein all details of equipments. Nevertheless the equipment shall be complete and operate in all aspects and shall conform to highest standard of engineering, design and workmanship. Any material or accessory which may not have been specifically mentioned but which is necessary or usual for satisfactory and trouble free operation and maintenance of the equipments shall be furnished.

1.13 Climatic conditions :The conditions under which the charger is to work are as follows :

3.20 Maximum ambient air temperature – 45 Deg. C.3.21 Minimum temperature of air in shade – 10 Deg. C3.22 Altitude – Not greater than 1000 Mtrs.3.23 Humidity – 85 to 100%

SECTION – IIDETAILS OF EQUIPMENTS

2 Design Criteria :

1.1 Design Basis :

1.11 The Battery Charger will constitute the D.C. power supply source for all station loads.

1.12 The equipment will be installed indoor in a clean but hot, humid and tropical atmosphere.

4.20 The Battery Charger combination shall be such as to ensure continuity of D.C. supply at load terminals at all times without even momentary interruption.

4.21 Further, the voltage at load terminals shall never exceed the limits of +10% and -15% of the nominal system voltage.

3 System concept :

a. The battery charging equipment shall be suitable for all modes i.e. for initial charging, trickle charging equalizing and hanging and boost charging.

b. The float charger will be normally ON, supplying the station load current and at the same time float charging the battery.

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c. The characteristics shall be such that if load is high and exceeds the charger capacity, the excess load will be supplied by the battery.

d. The boost charger will be normally in stand by (auto equalizing charge) mode and will cut into the circuit automatically to provide occasional equalizing charge as required.

e. The arrangement of end cell tapping if required will be provided, so that while Boost charging the battery, if AC supply fail or float charger feeding loads develop trouble, at least 42 cells i.e. (42 x 2.62 = 110 V) are connected across the load and part of the Battery continue to meet DC requirement till change over takes place and full battery is put across the load.

f. The boost charger shall also have provision for equalizing and boost charging the battery through manual selection.

g. On failure of the station A.C. supply both float and boost chargers will go out of service and battery will take over to supply station emergency loads without any interruption.

4 Technical Particulars :

The Technical particulars of the equipments are mentioned in the annexures.

5 Specific Requirements :

4.10 Layout

4.32 General :4 The charger shall be natured, air cooled, Zener type thyristor controlled full wave bridge

configuration. 5 The charger shall be provided with automatic voltage regulation, current limiting circuitary,

smoothing filter circuit limiting and soft start feature. 6 Voltage control shall be stepless smooth and continuous.7 The charger shall be self protecting against all AC and DC Transients and steady state abnormal

currents and voltages. 8 Charger AC input and DC output shall be electrically isolated from each other and also panel

ground. 9 Isolations shall be provided between power and control circuit. 10 Cooling :

Natural air cooling shall be employed in all units suitable .. with fine mesh or preparations are to be provided in the panels for this purpose. The use of fans etc., for including accelerated air flow is precluded. Oil cooled components are not acceptable.

11 Interface against Re-circuits :

The equipment shall be efficiently screened against interface to radio as also other communications equipment which may be installed in the same building. All the sources of noise shall be fitted with Re-suppressors generally in accordance with Rs. 613 or relevant ISS.

4.40 Gen. Structural Features :

The battery charger with all its accessories shall be mounted in all cubicle preferably in the front access which should be rigid of the self supporting type and fabricated with frame work of angle iron fitted with folded sheet metal (2.0 mm thick) panels. The cubicle shall be adequately ventilated and its sides shall be flush and free from projections viz. bolt heads etc., The base of unit shall be such as to rest directly on the floor and distribute the loads as uniformly as possible over the floor area.

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12 Indicating Instruments :Indicating instruments shall be of flush mount type with a dust tight and vermin proof covers. The instrument shall be of 96 mm. sq. dials shall be white, with black numbers and lettering. Instruments shall be of accuracy class 1.5.

j) Regulation :

The DC output shall be maintained at +/- 1, for input variation of +/- 10% from no load; to full load and in-put frequency variation from 47 Hz to 53 Hz. The power factor shall not be less than 0.65.

4.41 Wiring :The internal power and control wiring of the charger shall be of adequate rating as recommended by cable manufacturers.

The interconnecting cables or bus bars carrying load current from the main transformers secondary onwards upto and including DC output bus bars shall be of copper. Interconnecting leads in the control circuits and leads of filter capacitors shall also be of copper. Ends of all load current carrying cables shall be soldered or crimped effectively to the conductor to ensure that the temperatures rise at the joints does not exceed that of the conductors. All cabling and wiring shall be neatly secured in position and adequately supported. All cables and wire carrying AC supply shall be kept separate from other cables. The colour scheme employed for the cabling and wiring shall be shown in the supplier instructions manual. The colour scheme employed for the cabling and wiring shall be shown in the supplier instructions manual. The colour scheme employ shall be as follows :

i) For AC circuits - Grey ii) For DC circuits - “ “ Red

“ “ Black“Earth” – Green

a. Earthing :

In the unit, two “Power Earth terminals shall be provided in effective electrical contact with cubicle frame work. All metal parts of the components of the unit which do not carry current shall be connected thereto.

b. Training :

The frame work and the surface of the steel panels shall be send blasted to remove rust, scales and foreign adhering matters. Then the parts shall be given primary cost of rust resisting paint which shall be followed by two coats of opulence green corresponding to shade No. 275 of 15-05-1978. The finishing coat shall be polished cellulose or equivalent. Any other standard approved method regarding painting could be adopted.

a. Components of the charger :

The battery charger shall be supplied complete with all the devices including, but not limited to the following

2. a) One type – Zener type thyristor controlled bridge rectifiers with simple smoothening circuits.

3. a) One – Double wound air cooled Transformer of suitable rating with adequate number of primary off load taps at 210 V, 230 V, 25 V, 270 V and secondary tape for the charger output voltage/ current (for float charger) 1.2 KVA.

b) One – Double wound air cooled Transformer of suitable rating with primary off-load tape at 210 V, 230 V, 250 V, 270 V and secondary taps for trickle charger. c) One – Double wound air cooled transformer of suitable rating with primary off-load taps at 210 V, 230 V, 250 V, 270 V and secondary taps for boost charger – 3.5 KVA.

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4. Coarse and fins controls for manual control.

5. Regulator complete with manual/automatic selector switch.

6. One – Selection switch for mode of charging i.e. float charging/boot charging.

7. a) One – Voltmeter for AC input voltage. b) One – Voltmeter for the D.C. output voltage. c) One – Voltmeter for measuring boost charging DC voltage. d) One – Voltmeter for measuring float charging DC voltage.

7) a) One – Ammeter with centre zero for measuring boost charging of DC.

b) One – Ammeter for measuring DC float charging current. c) One ammeter for measuring load current. d) One centre zero ammeter to measure trickle charging current to

Battery as well as discharging current from the battery.

8) One set – Ripple filtering device to limit the ripple content to less than 2%.

9) One change over device to automatically change the charger operating mode from boost charge to float charge for a predetermined voltage condition. In the event of AC power supply failure or when the battery is being boost charged, available battery capacity shall be automatically transferred to the DC bus.

1 a) Fuses for DC output and AC input shall be brought on the front of the panel and cutouts provided.

b) Semi conductor devices, power failure, relay alarms on AC failure and to disconnect all internal charger loads from battery to prevent unnecessary discharging during power failure.

2 One internal cubicle light, operated on 230 V, single phase AC system with ON-OFF switch.

3 Two – Earthing lugs suitable for receiving 10 sq. mm copper conductor.

4 Cable glands for all external cables.

5 Printed circuits shall be accommodated in modules, plug in type and a similar modules shall be inter changeable in standard socket chassis.

6 Indicating lamps 1. Across the phase and neutral of the AC supply to indicate the healthyness of AC supply.

a) Across DC Voltage to indicate the supply “ON”.

7 Annunciation schemes :

A set of audible and visual alarm communication scheme with all necessary accessories to acknowledge reset and test scheme as also other necessary relays with the following facia windows.

i) A.C. Mains fail.ii) Float charger D.C. fail.iii) Boost charger D.C. fails.iv) D.C. Earth fault.v) Rectifier fuse fail.vi) Filter fuse fail.vii) Blocking Diode fail.viii) Load Bus DC fail.

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ix) Charger overload. As required.

17) a) Heat sink for boost charger.

b) Heat sink for float charger.

18) MCCB 9 KA with O/L and short circuit protection for the following : a) Boost charger output.b) Float charger output.c) Trickle charger output.d) AC input.

19) D.C. Distribution board for 4 Nos. of outgoing feeder. Each feeder shall be provided with 1 No. of 16 amps. of MCCB breaking capacity 5 KA.

4.41 Bill of materials with full details shall be furnished without which the offer shall be rejected.

SECTION – IIIOTHER TERMS AND CONDITIONS

1.00 Tests :3.1 Routine tests : During manufacture and on completion the equipment shall be subjected

to routine tests in accordance with latest relevant standards. 3.2 Type tests : Type test certificates as per-relevant standards shall be furnished by the

Vendor.

10.0 Type tests of Battery Charger : Radio frequency interface test. 11.0 Routine tests on Battery Charger.

i) Insulation resistance test.ii) Voltage regulation check from 0 to 100% load with +/- 10% voltage variation.iii) Ripple content measurement.iv) Heat run test on current limiting value.

12.0 Routine tests on component parts and accessories as per relevant I.S.

Test Witness :Test shall be performed in the presence of purchaser’s representatives as detailed under section – IV.

3.3 Test Certificate :Certified reports of all the tests carried out at the work shall be furnished in 3 copies for approval of the purchaser. The equipment shall be dispatched from works only after the receipt of purchaser’s written approval of Test reports.

2.00 Special Tools & Tackles:A set of special tools and tackles which are necessary or convenient for erection, commissioning, maintenance and overhauling of equipment shall be supplied.

1 Spare : The Vendor shall submit a list of recommended spare parts for three years and satisfactory and trouble free operation indicating the itemized price of each item of spares.

2 Drawings :

4.01 Tender Drawings: Duplicate copies of the relevant drawings shall be submitted with the tender.

4.02 Contract Drawings:

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Supplier shall submit drawings in quadruplicate for approval of the purchaser prior to manufacture. After the drawings are approved six copies of the drawing printed on 90 GSM paper shall be supplied for immediate use. The supplier should forward the drawings and literature (as detailed in clause 2.00) as follows :

a) One set of reproducible originals and 12 sets of blue print copies of all approved drawings along with 12 sets of literature, commissioning and maintenance manuals to the office of EIL.

b) Four sets of blue print copies of all approved drawings along with four sets of literature and manual to consignees in respect of each of the stations.

c) Non-supply or part supply of drawings, literature and manuals will be deemed as incomplete supply of switchboard.

d) Foundation drawings indicating the details of foundation bolts cable entries and trenches, etc.,

e) Elementary diagrams of all controls, metering, protection, amunication and other circuits, panel wise. All device shall be according to SA CODE.

f) Schematic diagram’s of PCB’s and charger.

g) Dimensional outline of charger drilling diagram and special mounting arrangement if any of each type of various devices.

3 Packing : The supplier shall provided such packing of goods as is required to prevent damage or deterioration during transport to their final destination, the packing shall be sufficient to withstand, without limitation, rough handling during transport and exposure to extreme temperature and open storage. The packing case, size, rate shall be taken into consideration where appropriate the remoteness of goods final destination and the absence of mechanized heavy handling facilities at all points in transport.

4 Deviation from Technical Modification :The Vendor shall furnish the details of deviation/modification proposed by him to improve overall performance of the system. The deviations shall be brought in the tender clause by clause as per Annexure.

5 Last Experience :The Vendor shall also furnish the details of similar battery supplied by them so far giving order reference name and address of the customer etc. also indicating the period of commissioning.

8.0 Schedule of requirements and desired delivery :This shall be as per annexure.

9.0 Schedule of Guaranteed Technical Particulars :

This shall be as per Annexure.

1 Inspection :\

All tests and inspection shall be made at the place of manufacture unless otherwise specially agreed upon by the manufacturer and the purchaser at the time of purchase.

Schedule of Guaranteed Technical Particulars of 110V Battery Chargers

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Sl. Particulars

1. Manufacturer’s Type & Designation :

2 Type of Rectifier and rating as per IS-3895-1966 with latest

version.

:

3. Input AC Supply :

a) Voltage

b) Current

c) No. of Phases

d) Frequency

:

:

:

:

4. Percentage Tap provided on the Transformer Primary. :

5 Boost / Quick Charge Current

Minimum

Maximum

:

:

6 Trickle Charge Current

Minimum

Maximum

:

:

7 Whether Auto / Manual feature is provided :

8 Whether Automatic change over from boost charging mode to

float charge is pro vided when A.C. Failure takes place.

:

9 Whether voltage across load is constant While boost / quick

charging the battery. :

10 Allowable limits to voltage variation on A.C. side for

satisfactory charging of DC side :

11 Instantaneous forward Voltage drop versus instantaneous

current at rated service (a graph to be enclosed) :

12 Instantaneous reverse current versus Instantaneous reserves

volts at ratted Service (a graph to be enclosed) :

13 Range of variation of DC Voltage and Device used for the

same :

14 Rated D.C. output for

a) Boost Charger.

b) Float Charger

:

:

15 D.C. Output voltage regulation from no Load to full load. :

16 Maximum ripple content :

17 Maximum permissible temperature rise over an ambient

temperature of 150C. :

18 Whether the charger is tropicalised :

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19 Over load capacity :

20 Duration of overload :

21 Efficiency at

a) 25% Load

b) 50% Load

c) 75% Load

d) 100% Load

:

:

:

:

22 Dimensions of the charger Width x Height x Depth in mm :

23 Weight of the Charger in Kgs. :

24 List of major accessories provided :

25 Other details :

TECHNICAL SPECIFICATIONS FOR BATTERY FOR 220 KVSTATIONS 2 X 220 VOLTS, 300 AH CAPACITY

1.0 SCOPE:

1.1 This specification covers the supply of battery system to feed the protection equipments and emergency lights in the 220 KV Receiving station.

1.2 This specification covers manufacture, supply & delivery, FOR destination of lead acid batteries with plante/ Tubular type positive plates of capacity 2 x 220 Volts, 300AH Capacity.

1.3 This specification covers supply erection & commissioning of the battery sets at the specified station.

2.0 SPECIFICATION FOR 2 X 220 VOLTS, 300 AH BATTERY SETS:

2.1 As detailed in clause 1.0 above, the battery sets are required for 220KV Receiving station.

2.2 The batteries shall be complete in all respects.

2.3 The battery shall be of lead acid type plante / tubular type positive plates and heavy durable, half pasted type negative plates confirming to IS : 1652 - 1651 latest version. The positive plates shall resist the foaming Action of the current during charge & discharge & retain its strength, rigidity, shape dimensions over the operating life of the plates.

2.4 STANDARD :- The batteries shall fully conform to the latest edition of IS : 1651 - 1652 or any other equivalent international Standard.

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2.5 CONTAINERS: -The batteries shall be supplied with closed top specially moulded plastic containers or hard rubber containers. The containers shall conform to relevant Indian Standards. In case the battery offered conforms to Standards other than IS- 1651/1652, a copy of the relevant standard should be enclosed to the tender.

2.6 Rating: the batteries are intended to supply power at 220V to the protection equipments in the receiving stations. Each battery set shall contain 110 cells of normal voltage of 2 volts. The batteries are required to supply indicating lamps, Trip coils & control scheme of breakers, relays & station emergency lighting etc.,

The following particulars shall be noted:

a) Normal voltage 220V

b) Float charge voltage 200-280

c) Equalizing charge voltage 190-300

d) Amperes hour capacity 10 :300 AHhours discharge rate

2.7 END CELL TAPPING: -

The tenders should clarify as to whether it is preferable to have end cell tapping arrangement in the battery banks in order to control the voltage of the load side, When the battery banks are being boost charged or not. If end cell tapping is recommended to regulate

the voltage across load, battery set supplier should agree to supply necessary switch to cut-in /cutout the cells as also end cells as loose item.

2.8 LUGS: -The lugs shall be plate type & shall have the form conforming to Indian / International Standards. The lugs of like polarity shall be connected either by lead burning of

horizontal shape or by bolts. The type of connection adopted shall be clearly indicated in the tender.

2 9 SEPARATORS: The separator shall be of wood, glass or other acid resisting material. They shall conform to relevant IS or International standards.

2.10 HYDROMETERS. - Hydrometers suitable for floating in any cell in the battery & with a reasonably long scale permissible for the depth of the cell & capable of reading specific gravity 1100 to 300 with sub-divisions 0.022 shall be provided. A wall Mounting type teak wood

holder for the hydrometer shall also be supplied.

2.11 ELECTROLYTE: - The full quantity of electrolyte required for the first filling with 10% extra shall be included in the offer, The electrolyte shall be supplied in Non-returnable acid resisting jars. The electrolyte shall generally confirm to IS - 266 of equivalent international standards.

2.12 SUPPORTING RACKS OR SPILLAGE:- The racks or stillage shall be designed for double row, double tier arrangement preferably & shall be made of the best quality teak - wood. It shall be protected with anti -sulphuric acid paint. The racks shall form part of the supply. When in position & tightened up no metal, except lead shall be exposed. The tenderer should agree to modify the battery layout arrangement if required to suit battery room dimensions of 7.4 x 5.7 m.

2.13 ACCESSORIES; - The tenderer shall quote unit prices for the following battery accessories. Item Quantity

a) Cell testing Voltmeter (range 3-0-3 volts) 1 No.b) Rubber apron 2 Nos.c) Rubber shoes (Knee height) 2 pairsd) Thermometer (mercury/ alcohol type)

(0º to 100 º C) 1 No.

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e) Glass funnels 2 Nos.f) Spanners 1 Setg) Acid resisting jars 4 points capacity 2 Nos.h) Rubber Gloves 2 pairs1) Rubber springs 2 Nos.

2.14 PACKING: - All materials shall be securely packed, crated & protected against mechanical damage in conformity with manufacturer's standard practice.

2.15 DRAWING: -

2.16 CONTRACT DRAWING Contractor shall furnish 3 sets of drawings for obtaining approval and shall supply six sets to the consignee, fully detailed dimensioned approved drawing of complete assembly, procedure for charging & satisfactory operation & maintenance of the batteries under service condition. Further one set of reproducible originals of all the approved drawings shall be supplied.

2.17 TESTS: - All tests shall be conducted as per standards 'in the presence of our Inspection engineers & test certificates in triplicate shall be furnished for purchaser's approval The equipment shall not be dispatched before obtaining the written approval of the purchaser.

2.18 TEMPERATURE CONDITION : The batteries are required to operate Under the following temperature conditions

Maximum temperature 45 degree centigrade.

Minimum temperature 5 degree centigrade

Average rainfall Varies from 1000mm to 2000mm

Height above M.S.L Below 1000 mtrs.

2.19 Necessary tools requried for site assembly shall be supplied by the contractor.

2.20 The Contractor shall furnish guaranteed Technical particulars as per DRS. The schedule of requirements & desired delivers are furnished vide Annexure-II. The tenderer shall furnish the details of experience as per Annexure V

220 VOLTS, 300AH BATTERY CHARGER

TECHNICAL SPECIFICATIONS FOR BATTERY CHARGERS WITH D.C. DISTRIBUTION BOARDS FOR VARIOUS SUB-STATIONS OF EIL - 220VOLTS, 300AH CAPACITY

1.0 Intent of Specification

This section of the specification covers design, manufacture, testing, supply and erection and commissioning of battery charger and DC distribution panel with all materials and accessories required for 220 kV receiving stations of EIL for boost ,float and trickle charging 220 kV,300AH battery set and for distribution of DC supply with efficient and trouble free operation to various equipment in receiving stations of the owner.

1.1 Scope

1.1.1 The brief requirement for each station is detailed below :

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a) A Charger – 1 panel consisting of a separate boost charger and separate float charger with trickle charging as detailed else where in the specification.

b) A Charger – 2 panel exactly similar to (a) above to serve as 100% stand by with suitable inter-lock so that either charger – 1 or charger – 2 is in service.

1.1.2 The battery charger together with the battery bank and DC distribution board shall constitute a 220V DC source for supply to various equipments in the main receiving stations. In addition to this, the charger shall be capable of being used for initial charging, trickle charging and equalizing charge as stipulated by battery manufacturer. The arrangement for end cell tapping, if required will be provided, so that while boost charging, the battery AC supply voltage fails or float charger feeding loads develops trouble, at least about 84 cells (84 x 2.62 Volts = 220V) are connected across the load and part of battery continue to meet the DC requirement till change over takes place and full battery is put across the load. The detailed circuit arrangement is explained else where in the specification.

1.2 CODES & STANDARDS:

All the equipments and materials shall be manufactured and tested in accordance with the latest

applicable standards.

1.3 COMPLETENESS OF SUPPLY:

It is not the intent to specify completely herein all details of equipments/ components.

Nevertheless, the equipment shall be complete and operate in all aspects and shall conform of

highest standard of engineering design and workmanship.

Any materials or accessories which may not have been specifically mentioned, but which is necessary or used for satisfactory and trouble free operation and maintenance of the equipment shall be furnished.

1.4 SERVICE CONDITION

The battery charger and its associated accessories shall be designed for operation in the following

climatic condition.

i. Maximum Temperature of Air in Shade 45°ii. Minimum Temperature of Air in Shade 5°iii. Average Daily Ambient Air Temperature in Degree C. 65°Civ. Maximum Relative Humidity 10-100%v. Altitude Less than 1000mmvi. Average rainfall 100-3000/5000mmvii. No. of rainy days per annum 100 Days (Max.)viii. Isoceraunic level days /year 46ix. Siesmic Level (Horizontal Acceleration). 0.3

All the equipments, accessories and wiring shall have tropical protection involving special treatment of metal and insulation against fungus, insects, and corrosion.

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1.5 DESIGN CRITERIA

1.5.1 The Battery charger will constitute the DC power supply source for all stations loads.

1.5.2 The equipment will be installed indoor in a clean but hot, humid and tropical atmosphere.

1.5.1 The battery charger combination shall be such as to ensure continuity of DC supply at load terminals at all times without even momentary interruption.

1.5.2 Further, the voltage at load terminals shall never exceed the limits of 10% and –15% of nominal, system concept.

1.6 System Concept

1.6.1 The battery charger panels shall consists of the following

a) A Charger – 1 panel consisting of separate boost and float charger suitable for charging, equalizing charging and trickle charging of 220V, 300AH battery sets besides meeting continuous and emergency DC loads as detailed else where in the specification.

The above modes of charging both automatically and manually shall be through manually operated Auto / manual selection switch.

b) The boost charger shall be capable of initially charging of the 220V, 300AH battery at quick rate after an emergency or after a discharge test or for giving periodical curative charge once or twice a year as per battery manufacturer’s recommendations.

c) The float charger shall always be connected to the DC load and shall maintain a steady voltage of 220V, plus or minus 0.5 % using a constant potential controller.

1.6.2 During normal condition the float charger shall be on and working in parallel with DC load and battery. The rating of the float charger shall be such as to meet the float charge current requirement of the battery plus the continuous DC load, the details of which is given else where in the specification. While boost charging the battery set shall be across boost charger and float charger shall be across the load.

1.6.3 During the boost charging, if there is an AC supply failure, the battery should automatically be connected to the load to maintain continuity of DC supply.

1.6.4 Further, to have battery supply across load even during short interval of change over period and if float charger develops trouble, the 84th cell of the battery should be capable of being connected through a blocker diode to the load so that under boost charging condition the float charger, the continuous DC load and battery up to 84th cell are in parallel. A charger – 2 panel exactly same as charger-1 panel is required as 100% stand by. There should be an interlock in the circuitry such that if charger No. 1 panel is in service, it should not be possible to put charger No. 2 panel into service and vice versa.

1.7 RATING :The ratings for boost charger, trickle charger, float charger and emergency lighting change over system shall be as detailed below :

Sl. No. Particulars Required valuea. Boost charger

i) Range of voltageii) Continuous current rating

220V, 300AH190 to 300V50 Amps

b. Trickle charger and float charger

i) Range of voltageii) Continuous current rating – floatiii) Trickle charger current

200 to 280 V20 Amps200mA Min800mA Max

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1.8 Detailed specification for charger panel.

The battery charger shall be supplied complete with all devices including but not limited to the following. If any device/components felt is required at the time of approval of drawings, the same shall be provided without any extra cost.

1.8.1 Each charger panel shall consists of –

a) A Boost charger operating on AC input voltage of 415 volts –30 % to +10%, three phase, 50hertz, + 5%, to give a DC output ranging between 190V to 300V so as to quick charge a bank of 110cells each of 2V from an end voltage of 1.75V to 2.65 / 2.7 V at a Max, continuous rate of 50 A and shall consist of the following components (boost charge current – start – 50A, finish 25 Amps).

i) One No. triple pole and neutral pole ON / OFF AC input switch of adequate rating.

ii) Required Nos. of HRC fuses with base, fittings etc. for DC output & AC input.

iii) Three Nos. of pilot lamps for indicating availability of 3 phase supply.

iv) One No. AC contactor triple pole with one normally open contact for controlling DC contactor connecting battery to the DC bus with overload release and one No. ON / OFF switch (for providing interlock between charger – 1 and charger – 2).

v) One constant potential controller for error detection, load current detection, amplification etc., so that the Boost charger output voltage is maintained automatically to the required value, with input voltage variation detailed above.

vi) One 3Ph naturally air cooled transformer liberally rated for the rectifier rating specified with + 2.5% taps on input side for input voltage correction by means of selection switch mounted on the front of the panel which can be operated on load for changing the taping of the input transformer.

vii) Three Nos. ballast chokes, if required.

viii) a) One set of 3- phase full wave bridge connected silicon rectifier, with zener type thyristor with simple smoothening circuits, liberally rated to meet the continuous current rating specified with stepless voltage control.

b) One set ripple filtering device to limit the ripple content to less than 2%

ix) One double pole moulded case circuit breaker backed by HRC fuses on DC output side.

x) A set of indicating lamps for DC on indication & A.C supply indication

xi) One DC ammeter moving coil type with shunt etc., for measuring DC output /charge / discharge current and one ammeter for measuring load current.

xii) One moving coil voltmeter with selector switch to read boost charge voltage, float charge voltage, battery tap and off and one volt meter for AC input voltage.

b) A float charger operating on AC input voltage of 415 V –30% to + 10%, three phase 50Hz + 5% to give a DC output ranging from 200V to 280V separately controlled to give a continuous variable load max 20 A and to give a trickle charge current of 200 to 800 mA the load current varying from 0-100% and consisting of the following components.

i) One AC input triple pole & neutral pole ON/OFF switch of adequate rating.

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ii) Three Nos. of HRC fuses with fittings.

iii) Three Nos. of pilot lamps.

iv) One No. AC input contactor with over –load releases and coil /ON /OFF switch.

v) One constant potential controller for error detection, load current detection, amplification etc., so that the float charger output is adjusted automatically such that the battery voltage is around 220 volts with load current and input voltage variation detailed above (both) occurring simultaneously.

vi) One auto manual change over switch.

vii) One raise / lower push button for manual operation.

viii) One main transformer, 3 phase, natural cooled, liberally rated for the rectifier rating specified with + 2.5% taps on input side for input voltage correction by means of selection switch mounted on the front of the panel which can be operated on load for changing the tapping of the input transformer.

ix) a) One set of 3 phase full wave bridge connected silicon rectifier with zener type thyristor with simple smoothening circuit liberally rated to meet the continuous current rating specified with step less voltage control.

b) One set of smoothing choke to limit the ripple content to less than 2%.

x) One moulded case circuit breaker to control float charger DC output.

xi) Required Nos. of HRC fuses with base fittings etc for DC output and AC input.

xii) One moving coil ammeter for float charger current.

xiii) One centrezero milli ammeter to measure trickle charging current to the battery.

c) IMPORTANT NOTE :

1. For each station two charger panels each consisting of one boost charger and one float charger detailed above shall be supplied.

2. a) Fuses for DC output and AC input shall be brought on the front of the panel and cutouts provided.

b) Semi conductors devices, Power failure, relay alarms on Ac failure and to disconnect all internal charger loads from battery to prevent unnecessary discharging during power failure.

3. Printed circuit shall be accommodated in modules, plug in type, and similar modules shall be interchangeable in standard socket chasis.

1.8.2 FOLLOWING COMMON EQUIPMENTS FOR CHARGER-1 & CHARGER-2 ARE REQUIRED.NOTE:

It may be noted that there are two banks of battery sets connected in parallel ie., 2 banks of 300AH battery sets in parallel total 600AH capacity. Normally one bank (300AH) will be service and the other bank (300AH) will be stand by. Typical switching scheme of twin battery charger for charging two battery sets independently is enclosed.

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i) 2 Sets of single pole two way on and off suitably rated change over switch for connecting one charger while disconnecting the other charger on DC side.

ii) Two sets of single pole two way on and off, suitably rated change over switch for selection of Battery Float/ Boost mode (one for each battery bank)

iii) 2 MCCB (one for each battery bank), triple pole for connection of 110th cell and 84th cell positive and for first cell negative.

iv) 2 DC Contactors, (One for each battery bank), for connecting the battery 110 th cell to bus positive through above MCCB.

v) Two silicon blocker diodes (one for each battery bank) for connecting 84th cell positive to positive of DC bus through the above MCCB.

vi) Suitable no. of earth leakage circuits for annunciation both audible and visual with push button for reset.

vii) Two sets of milli-ammeter (one set for each battery bank) to indicate the leakage current when the mid point of the battery is earthed.

viii) A set of audible and visual alarm annunciation scheme with all necessary accessories to acknowledge reset and test scheme as also other necessary relays, with the following facia window.

i. AC Mains fail ii. Float Charger DC Failiii. Boost Charger DC Failiv. DC Earth Faultv. Rectifier fuse failvi. Filter fuse failvii. Blocking Diode failviii. Load Bus DC fail ix. Boost charger over loadx. Float charger overloadxi. Under voltage of the batteryxii. Over voltage of the battery xiii. xiv. As required xv.

NOTE :All MCCB shall be of breaking capacity of 25 KA with over load and short circuit protection.

1.8.3 A DC distribution board consisting of :i) Electrolytic Copper insulated DC bus bars of adequate rating.ii) Ten circuits of 60 Amps with switch fuse unit consisting of suitably rated HRC fuses.iii) Ten circuits of 30 Amps with switch fuse unit consisting of suitably rated HPC fuses.ii) One set of automatic emergency light circuits of 10A rating with AC/DC contactors etc.

1.8.4 The necessary internal wiring, space heater, terminal blocks, panel to mount the equipments shall be provided.

1.8.5 The equipments not specifically covered in the above schedules but required for the satisfactory working of schematic arrangements detailed else where in the specification shall be provided by the supplier, giving all the details.

1.8.6 The makes of all equipments supplied shall be detailed. The equipments shall be carefully be selected such that only proven components are used particularly the diodes, thyristors etc., so as to give trouble free operation.

1.8.7 INTEREFRENCE AGAINST RE-CIRCUITS:

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The equipment shall be efficiently screened against interference to radio as also other

communications equipment, which may be installed in the same building. All the sources of noise

shall be fitted with Re-suppressors generally in accordance with relevant ISS/IEC.

1.9 DETAILS OF CHARGER / DC DISTRIBUTION PANELS :

1.9.1 The components detailed in clause 1.5.1 ie., of one boost charger and one float charger shall be mounted in separate panel. The components common to two charger panels detailed in clause. 1.5.2, shall be housed in common panel. The common, panel shall be accommodated in between two charger panels.

1.9.2 The panels shall have maximum height of 2.5 mtrs. and depth around 1.0mtr. It shall consist of completely enclosed self supporting cubicle type CRCA sheet steel enclosures for mounting various equipments. Each panel assembly shall have easily removable hinged door at the back with easy access for inspection and maintenance. The sheet steel shall be of minimum 3mm thickness where equipments are mounted on them and the side and back door sheets shall be mounted on structural steel of light but rigid sections. The bottom of the panel and frame works shall be suitable for mounting on slush concreate floor using evenly spaced ground bolts projecting through the base channel.

The equipment layout on the panel be such as to give neat appearance ease of operation of various equipments keeping the over all width to the barest minimum.

1.9.3 The rear, side and front enclosing, steel sheet shall be such as to have good ventilation particularly for the portion housing transformers etc.,

2.0 COOLING :

Natural air cooling shall be employed in all units. Suitable louvers with fine mesh or perforations are to be provided in the panels for this purpose. The use of fans etc., for including accelerated air flow is precluded. Oil cooled components are not acceptable.

2.1 FINISH :

All unfinished surfaces of the steel panels and frame work shall be rust proofed after fabrication and prior to painting and before applying the finishing coat, and an under coat suitable to a serve as base and binder for the finishing coat shall be given. The first coat on the exterior of panels shall be polished cellulose, enamel or equivalent and of colour to be indicated by the purchaser at the later date. The interior surface shall be finished stoved enamel white. A small quantity of finishing paint shall be supplied with each consignment of panels to enable the purchaser to restore at site any finish, which may get damaged during transit. The exterior colour of the panel shall correspond to shade no. 275 of IS-5. The interior of the panel shall be white enamel.

2.2 Buses, switching devices and connections :

All buses, switching devices and connections shall be of sufficient size to limit to the temperature raised to 45° C (Peak) inside the enclosure while carrying full load current. All main bus joints and bus to taps shall be silver plated and tightly clamped with through bolts to ensure maximum conductivity. All buses wherever possible shall be of rigid type. They shall be liberally spaced and so mounted that their expansion and contraction do not subject either the bars or the insulating supports to any stresses. Wherever required, suitable expansion joints shall be provided. All bus work and connections shall be accessibly for inspection and maintenance purpose from end to end rare, after first removing respective enclosing plates. All buses, AC & DC switches connections shall be designed to carry 25 KA for 1 second.

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2.3 Ground Bus :

For ensuring the rigid connection the minimum section of the ground bus shall not be less than 160 Sq. mm. The ground bus shall be earthed solidly and connected to the purchaser’s station main earthing system through 50 x 6 mm G.I flat with 2 bolts of M12 size.

2.4 SPACE HEATERS AND LIGHTING OUTLETS :

Space heaters shall be provided inside all cubicles and panels to prevent condensation of moisture. Wiring connection to the space heaters in the cubicles shall have suitable insulation over a safe length from the heater terminals. All lightning outlets with the switches etc., shall be provided inside each entrance door at the back of the panels.

2.5 WIRING

The internal power and control wiring of the charger shall be of adequate rating as recommended by cable manufacturers and relevant IS.The interconnecting cables or bus bars carrying load current from the main transformers secondary onwards upto and including DC output bus bars shall be copper. Interconnecting leads in the control circuits and leads of filter capacitors shall also be of copper. Ends of all load current carrying cables shall be fitted with copper lugs of adequate rating and shall be soldered or crimped effectively to the conductor to ensure that the temperatures rise at the joints does not exceed that of the conductors. All cabling and wiring shall be neatly secured in position and adequately supported. All cables and wire carrying AC supply shall be kept separate from other cables. The colour scheme employed for the cabling and wiring shall be shown in the suppliers instructions manual. The colour scheme employed shall be as follows :

i. For AC Circuits - Greyii. For DC Circuit - “Positive” -Red

“Negative” -Black“Earth” -Green

All outgoing wiring shall be brought out to terminals on terminal blocks provided with 10% additional terminals. The terminal end shall be provided with suitable identification marks. All the terminals shall be of nut and stud type of brass coated with nickel, not less than 8mm and suitably rated to carrying the respective rated current.

2.6 SPACE FOR CABLE AND CABLE GLANDS :

Sufficient space for receiving the cables inside the switch board on the bottom, cable glands and mounting arrangements for the feeders shall be suitable for PVC insulated cables. The size of the cables shall be intimated at later date.Necessary cable glands for all cables shall be included in the supply.

2.7 MIMIC DIAGRAM :

The mimic diagram shall be incorporated with red and green lamps for indicating air circuit breakers position. Switchboard purpose, built in resistor type lamps of low watt consumption inter changeable and suitable for easy replacement shall be provided. LED lamps are also acceptable.

2.8 NAME AND IDENTIFY PLATES :

Twelve mm (half inch) wide plastic plates bearing suitable identification marks shall be fixed on the exterior of the switch board in appropriate places to indicate the function of different switches, electrical devices, measuring instruments etc., and circuit breakers. Also suitable designation plates with details shall be provided for all equipments inside the panel.

2.9 EARTHING :

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Earthing of a dead metallic part of bodies of the equipment on the panels shall be done with a soft drawn single conductor bare copper. Main connection shall have minimum area of 14.5 mm and the main earthing connection to the earthing bus bar, 65 sq. mm these wires shall be connected to suitable terminals and clamp junctions. Soldered connections shall not be employed. The no. of earthing terminals shall be two for the whole assembly of panels.

3.0 INDICATING INSTRUMENTS :

All instruments shall be of the square switch board type, of 96 Sqmm. Size back connected, suitable for semi flush mounting and provided with dust light cases for tropical use with dull black enamel finish. The accuracy class shall be 1.5. The dials shall be made of such materials as to ensure freedom from wrapping, fading and discolouring. Marking on scales shall be black on white background. The dials of the instruments shall be of 2400 scale. All instruments shall have practicable laboratory means of adjustments to accuracy. The limits of error shall be those permissible for switchboard instruments as per IS-1248 or BSS-87. The instruments shall be capable of indicating correctly when operated continuously at any temperature from 00C to 500 C. Instruments shall be able to give correct indication at a temperature of 65 C for a period of 16 hours. Necessary test blocks shall be provided.

3.1 Regulation :

The DC output shall be maintained at + 1% for input variation of + 10% from no load to full load and input frequency variation from 47.5 Hz to 52.5 Hz. The power factor shall not be less than 0.65.

3.2 TESTS OF FACTORY :

The equipment and panels shall be tested in accordance with relevant ISS or BS or equivalent standards.

3.2.1 ROUTINE TESTS :

During manufacture and on completion the equipment shall be subjected to routine tests in accordance with latest relevant standards.

3.2.2 TYPE TESTS :

Type test certificates as per relevant standards shall be furnished by the tenderer.a) Type tests of battery charger : Radio Frequency interference test.

b) Routine tests on Battery charger :-i) Insulation resistance testii) Voltage regulation check from 0 to 100% load with + 10% voltage variation.iii) Ripple content measurement iv) Heat run test on current limiting value

c) Routine tests on component parts and accessories as per relevant IS.TEST WITNESSTest shall be performed in the presence of Purchaser’s representatives.

3.3 CONTRACT DRAWINGS:The supplier shall submit four copies of the following drawings for approval.

i) Details of construction of cubicles and complete drawings of the switch board indicating full details of the location switches, instruments, relays, bus bars, cable glands, support etc.

ii) Wiring and cabling diagram for all the circuits. All devices shall be numbered according to the international convention.

iii) Details of construction of boost and float charger.

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3.3.1 SUPPLIER SHALL FORWARDAfter the drawings are approved six copies of the drawing printed on 90 GSM paper shall be supplied for immediate use. The supplier should forward the drawings and literature as follows :

a) One set of reproducible originals and 12 sets of blue print copies of all approved drawings along with 12 sets of literature, commissioning and maintenance manuals to the office of the Chief Engineer, Electy., Transmission zone, EIL.

b) Four sets of blue print copies of all approved drawings along with four sets of literature and manual to consignees in respect of each of the stations.

c) Non-supply or part supply of drawings, literature and manuals will be deemed as incomplete supply of switchboard.

d) Foundation drawings indicating the details of foundation bolts cable entries and trenches, etc.,

e) Elementary diagrams of all controls, metering, protection, annunciation and other circuits, panel wise. All devices shall be according to SA CODE.

f) Schematic diagram’s of PCB’s and charger.

g) Dimensional outline of charger drilling diagram and special mounting arrangement if any of each type of various devices.

1.0 BATERRY CHARGER

1.1 GENERAL

1 . The charger shall be natural air-cooled thyrister controlled type.

2. The charger shall be self protective against all AC and DC voltage transient and steady/abnormal currents and voltages.

3 The charger must of soft start type and shall not exceed the set voltage even at start

4. They shall be capable of operating in 'manual' and 'Auto' mode.

5. They shall be capable of operating in 'Float' and 'Boost' mode.

6. The charger shall resume feeding DC loads automatically immediately after AC supply is resumed following an interruption.

7. Normally each station will be provided with two numbers of chargers and two numbers of battery sets feeding two independent loads. In case of emergency, a single charger will have to charge two sets of battery and the entire load.

1.2 Construction

The charger shall be free standing, independent floor mounted sheet steel type.

2. The panels shall have a high degree of protection and the minimum thickness of sheet steel used shall be 2 mm.

3. The DC distribution board's shall be a separate panel and situated in between the two independent charger panels..

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4. Each charger and DCDB shall have independent access door with concealed hinges and 'neoprene' gaskets. Ventilating louvers shall be covered with fine wire mesh. Doors over 600mm Width shall be of double leaf design.

5. All equipment within the panels shall be arranged in modular unit and laid out with sufficient space for easy maintenance.

1.3 Wiring/Cabling

1. All interconnecting cables shall be of adequate rating and of multi-strand copper. The busbars provided shall also be of copper. The rating and size of a cables used shall be shown in the drawings to be submitted for approval.

2. The ends of all cables, control wires secured by means of clamps etc, shall be fitted with copper lugs of adequate rating and shall be soldered or clamped effectively to the conductor to ensure that the temperature rise at the joints do not exceed that of the conductor.

3. All wiring shall be routed through wiring troughs, wires shall be ferruled at both end for identification.

4. Panels shall have removable gland plates at the bottom for cable entry. All incoming and outgoing cable shall be terminated to suitable terminal blocks.

5. All terminals shall be clearly indicated with polarity indications. The terminal blocks shall be separate for AC supply, DC supply and control.

6. wiring shall follow color code scheme described below.

Colour of the core Circuit where used

* Red D. C + ve* Black D.C - ve* Grey A.C supply

Charger Equipment

The float-cum boost charger shall meet the following current and voltage characteristics

a) Input voltage 415V – 30% to +/-10% , 3 phase 4 wire 50 Hz A.C.

b) Output voltage 40 to 70 volts D.C

c) Load current 40Amps

d) Battery current 30 Amps

e) Total current 70 Amps2. The charger must have the facility for setting the current limit and output

voltage at predetermined values

3 Manual resetting type mini circuit breakers of suitable rating shall be provided on A.C side of the charger for automatic tripping of the AC supply to the charger in case of DC over voltage or over load conditions.

4. The variation of the DC voltage shall be within +/- 1% for a variation in input AC supply voltage of :L- 20% and for a output current variation from no load to full load.

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5. Provisions for adjusting the DC output in all mode of operation shall be provided. Provision for adjusting the upper limit of current shall also be provided in the auto mode. Potentiometer used for such adjustment shall be located on the front side of the panel and shall be calibrated in 3 or 4 ranges marked

6. Provision for boost charging the battery while keeping the voltage at load terminal from 46 volts to 52 volts by means selector switch (preferably 4 positions) to select the required number dropper diodes.

7. It shall have provision for automatic bypassing of dropper diodes and disconnection of bleeder resistor in case of failure of AC supply and also in case of failure of DC source to control circuits of charger.

8. The float cum boost charger shall also incorporate the following devices

a) One set of potentiometers for selecting output voltage in the following, modes of operation:

1. Manual

2. Boost

3. Float

b) One set of potentiometer for setting the voltage and current limit in auto mode.

c) The wound air-cooled mains transformer of sufficient rating shall be used for the charger and all details such as VA rating etc., shall be furnished. The tap selection shall be of half load type. The following taping shall also be provided.

Single phase 200,230,250 V

Three phase 380,415,450 V

d) one set of ripple filtering device to ensure that ripple content less than 500 mv

e) One set of automatic voltage regulator units. The regulators PCB's must be connected to the external circuit using fixing type sockets and connectors

f) Separate fuse protection shall be provided for AC_ supply, DC load, battery, capacitor bank- and control circuits.

g) Indicating meters of suitable rating to indicate:

1. Output DC voltage at load end battery terminals

2. One Ammeter to indicate total DC current

3. One centre Zero ammeter to indicate charge/discharge current through battery set

h) All indicating shall be of flush mounted type with dust proof covers.

The instruments shall be square shaped with minimum dimension of 96mm x 96mm. The dial shall be white in color with black numbers and lettering.

Indicating lamps to indicate the healthiness of AC supply and DC output shall be provided in the front side of the panels.

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j) One set spare. heaters with "ON and OFF " switch.

k) One lamp of sufficient voltage working on single phase AC to illuminate the interior of the battery charger ON OFF switch to be provided.

1) All semiconductor devices used for rectification of AC supply shall be protected using semiconductor HRC fuses which shall be fast acting.

m) The charger shall be effectively screened against causing interference to radio and other communication equipments which may be installed in the same row. They shall be fitted with RF suppressers.

n) The supplier of the charger shall take note of the fact that the DC positive (+ ve) lead of the charger will be maintained at ground potential.

o) Alarms : Audio and visual alarms shall be provided to indicate the following minimum points

i) Any fuse failure

ii) Under voltage

iii) Over voltage

iv) AC mains failurev) DC output failure

vi) Bridge diode SCR fuse failure

vii) Filter fuse failure

viii) Overload

The arrangement shall be such that on occurrence of a fault, the corresponding, window will light up and stays lighted until the fault is cleared and reset button is pressed. Each time a window lights up, a master relay shall get energized to provide audible alarm in addition to group alarm signals for purchaser's remote panel. The audible alarm shall stop on acknowledgement of the fault.

1.5 EARTHING

Two power earth terminals to be provided to make effective electrical contact with the panel frame. All metal part components of the units, which do not carry, current, shall be connected thereto. Two ear thing lugs suitable for receiving 10 sq. mm copper conductor shall be provided to the terminals

1.6 PAINTING

The panel shall be chemically cleaned phosphated and sprayed with two coats of high quality primer and stoved after each coat. The color of enamel paint to be used for finish shall be light gray.

Sufficient quantity of touch up paint shall be furnished for application at site.

1.7 The following tests on battery charger shall be carried out

1. Dielectric tests

2. Voltage regulation check from 0% to 100% load at input supply variation

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3. Ripple content measurement

4. Heat run test.

5. Test on current limiting value.

6. Routine test on component parts.

Necessary type testes as per relevant international standards shall be performed.

Tests shall be performed in the presence of Board's representative and the specified reports of the tests carried out at works shall be furnished for approval.

1.8 BATTERY SET

1.9 The specification covers the design, manufacture testing at works and supply of 48 V, 100 AH battery with a battery stand, inter cell/ row connections and accessories complete as per in 1651. The batteries are required to provide DC supply (48 Volt) to PLCC equipment.

2.0 GENERAL:

The battery shall be lead acid type with 'plante' positive plates

The plates shall be designed for maximum durability, during all service conditions including high rate of discharge and rapid fluctuations of load.

2.1 CONSTRUCTION

a) Each cell shall be assembled in heat resistant shock absorbing Robust, clear glass or polymer container the float type I level indicator.

b) Electrolyte level shall be marked on the container or external level indicators shall be provided. The marking as shall be for upper and lower limits.

c) Sufficient sediment space shall be provided so that the cells will not have to be cleaned out during normal life.

d) Open type cells shall be provided with suitable spray arresters and separate perforated transparent plastic covers; anti-splash type vent plug shall be provided for type cell.

e) Separator between plates shall permit free flow of electrolyte. Separator shall be of acid resisting materials.

f) The cells shall be supported on porcelain insulator fixed on to the rack with adequate clearance between adjacent cells.

g) The battery shall consist of 24 cells of 2 volts each and of 100 AH capacity at 10 hours discharge rate.

h) The cell terminal posts shall be provided with connector.bolts and nuts effectively coated with lead to prevent corrosion.

i) Lead or lead coated copper connectors shall be furnished to connect up ceils of battery set.

j) Positive and negative terminal posts shall be clearly and indelibly marked for easy identification.

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k) Lead coated bent copper plate, tubular copper lugs, teak wood clamp, bolts, nuts, washers etc., shall be furnished for connection of outgoing aluminium conductor cables. Where the cells are called upon to discharge at very high rates, the fitness of lead coating of connectors shall be heater than 0.025 mm.

2.2 RACKS

a) The racks for supporting battery cells shall be designed for double row double tier arrangement and shall be constructed of best quality teak-wood, painted with at least three coats of anti-acid black paint.

b) Rack shall be free standing type, mounted on porcelain insulators.

c) Porcelain number plates for each cell shall be provided for being fixed on to the racks,

2.3 TESTS

The supplier shall carry out necessary tests for local action, internal resistance, efficiency test and other routine test as stipulated in relevant IS

The bidder should furnish along with his bid copies of the type and routine test conducted on similar equipment in accordance with relevant standards.

2A Fitting and Accessories:

Each battery set shall be furnished complete with the following:

a) First charge of electrolyte +10% extra over the required quantity.

b) Teak-wood racks, three coats of anti- acid paints.

c) Strand insulators plus 5% extra on and above the required quantities.

d) Cell insulators plus 5% extra over the required quantity.

e) Cell inter connectors and take - off.

f) Cell numbering tag with fixing arrangements.

g) Teak wood cable clamps with hardware.

The following accessories shall be supplied along with battery set for each station.

a) One (1) inter connector bolt wrench.

b) One (1) Hydrometer syringe.

c) One (1) Thermometer with specific gravity correction scales.

d) One (1) cell testing voltmeter with leads.

1. D. C -Distribution Board (DC DB)

The panel housing the DC Distribution Board shall be similar in construction to that of the charger. Each charger shall be provided with an independent DC Board. Suitable interlock to prevent paralleling of two DC sources shall be provided.

2. The DC .D.B be designed such that:

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a) The DC output of the charger and battery set is terminated on to DC busses inside the D.C.D.B. The charger connections shall be taken through circuit breakers and DPDT switches.

b) Twenty (20) feeder outlets of 10 Amps., capacity each with fuse protection to be provided in each of the DC distribution board. It shall be possible to transfer any feeder on to any of the charger.

c) One voltmeter with selector switch shall be provided to indicate bus voltage. 2 Ammeters One each for each source.

d) A detailed sketch indicating the construction and wiring of the D.C.D.B and the mode of various controls, shall be furnished.

e) Indicating Lamps shall be provided wherever necessary.

f) A single line diagram indicating the path of control shall be incorporated in the front panel of the D.C.D.B.

g) DB shall be fully assembled wired and tested at factory.

h) The bus bars-wiring, and other conductor materials shall be of copper only.

2.6 TESTS AND INSPECTION:

2.7 The type of test and routine tests shall be carried out in the presence of owner's representative as per the IS applicable to that particular equipment.

2.8 If IS does not exist for any equipment, the testing shall be in accordance with IEC. In other cases the bidder shall furnish the details of the tests that will be carried out.

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