SPECIFICATION FOR POWER BATTERIES

Transcription

1 KAKRAPAR ATOMIC POWER STATION UNITS & (0 MWe) PROCUREMENT SPECIFICATION NO. KAPS/534/PB SEPC./00 SPECIFICATION FOR POWER BATTERIES Prepared By: Checked By: Reviewed By: Approved By: Kapil Mishra SO/E, EMU Ulhas Pethkar SO/F,KAPS P. Barik SME(E), KAPS S K Deshmukh MS V K Sharma CS-KAPS REVISION NO. : R DATE : Oct-06

2 Revision Control Sheet Document type: Technical Specification Document No: KAPS/534/PB SEPC./00 Title: Specification for Power Batteries of KAPS (Kakarapar Atomic Power Station- & ) Rev. No. Date Ro Oct-05 R Oct-06 Description of Revision First issue Revision in specification as per designer review Prepared by Checked By Reviewed by Approved by Kapil Mishra SO/D, EMU U Petkar SO/F, EMU Kapil Mishra SO/D, EMU U Petkar SO/F, EMU P Barik SME(E) P Barik SME(E) S K Deshmukh MS S K Deshmukh MS V K Sharma CS-KAPS V K Sharma CS-KAPS

3 NUCLEAR POWER CORPORATION OF INDIA LIMITED ( A Government of India Enterprise ) KAKARAPAR ATOMIC POWER STATION UNITS & SPECIFICATION FOR POWER BATTERIES SPECIFICATION No.: KAPS/534/PB SEPC./00 Revision Oct-06

4 Technical Specification for Power Batteries for KAPS- &. SECTION : CONTENTS Tender document CONTENTS SHEET OF Revision-0 SECTION TITLE NO.OF SHEETS CC- Scope of Supply/Work/Services 3 CC- Applicable Codes, Standards and Specifications CC-3 Specification of Main Equipment and Accessories 5 CC-4 Equipment Construction & Design Details CC-5 Inspection & Testing 8 CC-6 Quality Surveillance 3 CC-7 Tender Evaluation CC-8 Tests at Site 3 CC-9 Special Tools & Tackles for Erection & Maintenance CC-0 List of Drawings enclosed CC- Annexures D. FORMAT FOR SUBMISSION OF PART I (TECHNICAL) OF THE TENDER D Technical Data 8 D. Schedule of proposed equipment manufacturer s General Particulars D. Schedule of Tenderer s Experience D.3 Drawings to be submitted along with the Tender D.4 Performance Data, including performance curves, etc. to be Submitted along with the tender D.5 Schedule of submission of drawings, data, instruction manuals, Test reports etc. D.6 Schedule of Performance Guarantee D.7 Schedule of Deviations from Technical Specifications D.8 Schedule of Manufacturing, delivery and other related activities D.9 Schedule of Personnel for Erection, Testing & Commissioning SPECIFICATION No.: KAPS/534/PB SEPC./00 Oct-05

5 Nuclear Power Corporation Of India Limited Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& SCOPE OF SUPPLY/WORK/SERVICES Section : CC Page of 3 Rev-.0 This specification covers (i) removal of existing batteries along with stands (ii) Shifting of old battery from installed battery room to supplier premises (iii) design and supply of new batteries, material, construction features, manufacture, inspection and testing either at the manufacturer s works or independent test venue (iv) packing, safe transportation and delivery at site along with Loading/Unloading at KAPS store and shifting material from store to battery room (v) erection, performance testing at site and commissioning of batteries listed below with all accessories, spares complete in all respects as described in this specification for 0 MWe PHWR Kakrapar Atomic Power Station Units- &. Sr. No. Battery Designation Ampere Hour Capacity (min) Locati on 354 V DC POWER BATTERIES (77 no cells/bank) along with stands 534-BY- Tubular battery (TBS- Lead acid cells with tubular positive plates and pasted negative plates housed in SAN TB- & (06 M EL) transparent containers): 435 AH (Min.)* KAPS- Quantity KAPS- 534-BY- Tubular battery (TBS- Lead acid cells with tubular positive plates and pasted negative plates housed in SAN transparent containers): 435 AH (Min.)* TB- & (06 M EL) Tag No. of equipments supplied for KAPS- shall be pre-fixed by and those for KAPS- shall be prefixed by. * : Size indicated is minimum as acceptable by purchaser. However actual battery size offered by supplier shall be supported by detailed sizing calculation for duty cycle indicating all margins as indicated in CC-3 for offered battery.0 The SUPPLIER shall remove the existing battery banks along with battery stands, power cables from Turbine building and arrange transportation of the removed banks to Purchaser s store at site. All tools and tackles required for removal of battery shall be arranged by the SUPPLIER 3.0 Any civil work involved in removal of existing battery banks and installation of new battery banks and required tools, tackles and consumables shall be in the scope of SUPPLIER. SPECIFICATION NO: KAPS/534/PB SEPC./00 July-03

6 Nuclear Power Corporation Of India Limited Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& SCOPE OF SUPPLY/WORK/SERVICES Section : CC Page of 3 Rev- 4.0 The supplier shall arrange to take back the old battery cells, used electrolyte, battery stands, inter-cell, inter stand connectors etc under buyback offer. It will be supplier s responsibility to arrange safe transportation of removed battery banks, its safe disposal including electrolyte as per applicable Govt. of India rules and regulations. 5.0 The Tenderer shall offer lead acid batteries for tubular positive plate type (TBS). The batteries along with stands shall be complete in all respect with required inter-cell, inter-stand, inter-row connectors, end take off connections and shall be suitable for PURCHASER's external connections. 6.0 The batteries shall be shipped dry uncharged with transit cap along with electrolyte in separate, non returnable containers. 7.0 It will be SUPPLIERS responsibility to shift new battery banks & electrolyte along with stands from stores to place of installation in Turbine building. Complete erection & commissioning shall be responsibility of the SUPPLIER. Any tools, tackles and consumables (material & tools e.g. cable glands, lugs, crimping tools etc.) required for erection & commissioning shall be arranged by the SUPPLIER 8.0 Battery designations, and their typical room layouts are shown in drawings listed in Section CC The battery cells should be firmly supported and mounted on the racks to be supplied by Contractor with all interconnections between cells, considering the seismic withstand requirements. 0.0 SUPPLIER shall provide the double earthing to battery stand, supply of earthing cable and proper fixing shall be in the scope of SUPPLIER..0 It is under the scope of supplier to connect the new battery bank with UPS DC BUS with proper routing and support. All material required for connection including cable and cable trays will be in the scope of SUPPLIER..0 SUPPLIER shall provide and install the insulating mats in the battery room after installation of the new battery banks. Insulating Mats shall be suitable for acidic environment of battery room. 3.0 Spare parts and maintenance tools, as described in Sections CC- of this Specification, shall be supplied by the SUPPLIER. SPECIFICATION NO: KAPS/534/PB SEPC./00 July-03

7 Nuclear Power Corporation Of India Limited Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& SCOPE OF SUPPLY/WORK/SERVICES Section : CC Page 3 of 3 Rev- 4.0 SUPPLIER shall supply one trolley for handling, lifting and shifting of battery cells. 5.0 Whether called for specifically or not all accessories required for normal operation of equipment are deemed to be considered as a part of the SUPPLIER's scope of supply. 6.0 The SUPPLIER shall not sub-contract any of the work without a written consent from the PURCHASER. The SUB-CONTRACTOR shall be approved by the PURCHASER. 7.0 It is not the intent to specify completely herein, all details of design and construction of the equipment. However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and be capable of performing in continuous commercial operation upto the SUPPLIER's guarantees in a manner acceptable to the PURCHASER, who will interpret the meaning of drawings and specifications and shall be entitled to reject any work or material which, in his judgement, is not in full accordance therewith. 8. The CONTRACTOR shall indicate in section-d of the tender the guaranteed technical particulars for various items covered under the tender. The guaranteed performance particular shall conform to the tender requirements and the item supplied shall comply with the guaranteed particulars and technical specifications. SPECIFICATION NO: KAPS/534/PB SEPC./00 July-03

8 Technical Specification for Power Batteries for KAPS- &. Tender Document Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS- & APPLICABLE CODES, STANDARDS AND SPECIFICATIONS Section: CC- Sheet of R.0 The design, material, construction, manufacture, inspection, testing and performance of batteries and associated accessories supplied shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the SUPPLIER of his responsibility. Where no standards are available, the supply items shall be of good quality and workmanship and backed by test results. Any supply items which are bought out by the SUPPLIER shall be procured from MANUFACTURERS approved by the PURCHASER..0 Equipment shall conform to the latest applicable standards and codes of practice as mentioned in this specification. In case of conflict between the standards, the most stringent specifications among those standards shall govern, whereas in case of conflict between the standards and this specification, requirements of this specification shall govern. 3.0 Other National Standards are acceptable if they are established to be equivalent to or superior to the listed standards subject to approval by the PURCHASER and the SUPPLIER shall provide English version of standards and codes applicable. 4.0 The batteries, accessories and battery rack installation shall conform to the currently applicable standards and codes of practice and reports as listed below. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS/IEEE/IEC codes of practices as listed below. CODE TITLE ) IS:66 Sulphuric Acid. ) IS:069 Quality tolerances for water for storage batteries. 3) IS:46 Rubber and plastic containers for lead-acid storage batteries. 4) IS:65:03 Stationary cells and batteries, lead-acid type with Tubular positive plates. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

9 Technical Specification for Power Batteries for KAPS- &. Tender Document Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS- & APPLICABLE CODES, STANDARDS AND SPECIFICATIONS Section: CC- Sheet of R CODE TITLE 5) IS:885 Electrotechnical vocabulary: (Part VIII) Secondary cells and batteries. 6) IS:36 Sealing compound for lead-acid batteries. 7) IS:4905 Methods for random sampling. 8) IS:607 Synthetic separators for lead-acid batteries. 9) IS:830 General requirements and methods of test for lead-acid storage batteries. 0) IEEE:344 Recommended practice for seismic qualification of Class-E equipment for Nuclear power generation station. ) IEEE:450 Recommended practice for maintenance, testing and replacement of large lead storage batteries for generating stations and sub- stations. ) IEEE:484 Recommended practice for installation design and installation of large lead storage batteries for generating stations and sub- stations. 3) IEEE:485 Recommended practice for sizing large lead storage batteries for generating stations and substations. 4) IEEE:535 Standard for qualification of Class-E lead storage batteries for Nuclear power generating stations. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

10 Technical Specification for Power Batteries for KAPS- &. Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& SPECIFICATION OF MAIN EQUIPMENT AND ACCESSORIES Section: CC-3 Sheet of 5 R.0 This section covers the specific requirements for lead acid batteries: DATA SHEETS Technical Requirements for Lead Acid Batteries: SR. NO. DESCRIPTION POWER BATTERIES. Application Stationary battery for DC back-up to Power UPS. Type of cells Lead acid cells with Tubular type positive plates(tbs Type)..3 DC System Voltage.3. Nominal Voltage 354 V DC (77 x.0 V).3. Maximum Voltage during: (a) Boost charging (b) Equalizing Charging (c) Float charging.3.3 Minimum battery voltage during duty cycle discharge.4 Cell voltages.4. Float voltage Up to 490V DC Up to 45 V DC Up to 400 V DC 30 V DC.8-.8 VPC.4. Equalizing voltage considered.4 VPC.4.3 Max. Boost voltage considered.4.4 End of duty cycle discharge voltage.5 Guaranteed load duty cycle current on battery till its end of cell voltage as per.4.4 considering no. of cells as per clause.7.75 VPC.7 VPC Battery should give minimum back up time of 30 ampere DC and Power battery bank should also capable to give DC back up of 08 hrs as per attached load duty cycle (Annexure-I). SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

11 Technical Specification for Power Batteries for KAPS- &. Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& SPECIFICATION OF MAIN EQUIPMENT AND ACCESSORIES Section: CC-3 Sheet of 5 R.6 Guaranteed Duty cycle discharge current requirement for new battery at 7 Deg C. (Inclusive of AM, DM and Temp correction factors).7 No. of Cells in series in Battery Bank.8 Other factors to be considered, if any..9 Ref. room ambient temp for design of battery As per manufacturer s battery characteristics curve applicable for offered battery and power battery should give minimum back up of 30 A DC and power battery bank should also be capable to give DC back up of 08 hrs. as per attached load duty cycle (Annex-I) 77 Cells The vendor shall review and state if any other factors are required to be considered for selecting proper AH capacity of the battery in order to meet the intent of specification as defined by the duty cycle through out its design life when operated in float mode as detailed in the specification & called upon to discharge at any instant. Vendor shall submit the detailed calculation sheet of battery sizing considering design margin, temp. correction factor, ageing factor. 8 to 45 Deg.C.0 Charger details.0. Type of charger Modified constant voltage with current limit..0. Charger DC voltage steady state stability + %.0.3 Ripple voltage Limited to % of voltage without battery connected..0.4 Ripple current Shall be limited to 5% of C0 discharge current.0.5 Current limit during charging.0.6 Maximum time the battery can take for recharging after a duty cycle discharge so that it is again ready for a second duty cycle discharge Max. % of C0 Capacity 8 Hrs. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

12 Technical Specification for Power Batteries for KAPS- &. Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& SPECIFICATION OF MAIN EQUIPMENT AND ACCESSORIES Section: CC-3 Sheet 3 of 5 R. Minimum accepted C0 AH capacity for the battery banks Tubular Positive Plate. Factors to be considered for battery sizing 435AH 435 AH will be minimum accepted capacity, however supplied battery should meet all other specification and battery bank of 77 no. of cells shall give minimum back up of 30 A DC and power battery bank should also be capable to give DC back up of 08 hrs. as per attached load duty cycle (Annex-I) Design margin: 0%, Aging Margin: 5%, Temperature correction factor: 7% SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

13 Technical Specification for Power Battery for KAPS-& SPECIFICATION OF MAIN EQUIPMENT AND ACCESSORIES Section: CC-3 Sheet 4 of 5.0 LIST OF ESSENTIAL SPARES & ACCESSORIES TO BE SUPPLIED Following is the list of spares & accessories for testing and battery bank maintenance of lead-acid Sr. Item Description No. SPARES/ACCESSORIES/CONSUMABLES Quantity. Insulators for battery racks (if applicable) 50 Nos. Electrolyte of applicable specific gravity at 7 0 C 5% of total quantity 3. Inter cell connectors with hardware 0 Nos 4. Inter row connectors with hardware 5 Nos 5. PVC/Polystyrene spill trays (if applicable) under cells Sufficient for min. 0 Nos of cells 6. Vent plugs assembly 50 Nos 7. Spare nuts, bolts & washer 5% of total quantity 8. Inter cell insulated caps 0 Nos 9. Approved type digital multimeter RISHABH make, model RISH Multi 8 S or equivalent 5 Nos 0. Approved type digital hydrometer (Density meter) 3 Nos. Approved type portable digital hydrogen concentration in air meter with range covering up Nos to minimum of 4 %. Acid resistance jugs of adequate capacity with quantity markings. 5 Nos 3. Acid resistance funnels 5 Nos 4. Acid resistance Bucket 5 Nos 5. Rubber aprons and gloves 50 Nos 6. Digital PH meter and conductivity meters 5 no. each 7. Cell lifting straps (if required) 5 Nos 8. Insulated spanner set & Insulated torque wrench covering all sizes of hardwares used in the battery Nos bank. 9. Syringe for handling electrolyte in cells 5 Nos 0. Filling plugs. 50 Nos. Under cell marine plywood for each stand (if applicable) 0 % of total qty subjected to min. of one number. SPECIFICATION NO: KAPS/534/PB SEPC./00 July 03

14 Technical Specification for Power Battery for KAPS-& SPECIFICATION OF MAIN EQUIPMENT AND ACCESSORIES Section: CC-3 Sheet 5 of 5 Spare Battery racks of each type One number.. Approved type cell handling cum loading/ unloading trolley &/or set up for removal & installation of cells in racks & handling the cells 0 Nos from site storage area to battery room & vice versa 3. Petroleum jelly of approved make in Kg pack for application on battery terminals/ connectors. 00 Kgs 4. Spares cells (dry) - (combination of quantity for end & intermediate cells subjected to approval) 5 Nos 5. Spare containers & lids 0 Nos 6. Cell lid Sealing compound 0 Kgs/ Ltrs 7. Filler hole thermometer suitable for measuring battery electrolyte temperature. 08 nos. 8. Wall mounting type digital thermometer for battery room temperature measurement. 9. Laminated wall mounting type. Instruction cards indicating battery details, Battery TAG no., safety, operation & maintenance instructions. 08 nos. 08 nos. NOTE: ) One set of any item of spares shall include the quantity of all sizes and types of that item. ) The TENDERER shall also include such additional items in the spares offered which are not covered in the list above but which are necessary for the satisfactory operation and maintenance of the equipment offered. The details of such "additional spares" included together with details of quantities and unit rates shall be included in Section: D (Schedule of Spare Parts) and Section: E (Schedule of Prices) respectively as "Recommended Spares". 3) In case the TENDERER feels that the quantities indicated in the list of spares above need to be modified, details of the same including quantities of each item actually used and quantities of corresponding spares recommended shall be included in Section: D. SPECIFICATION NO: KAPS/534/PB SEPC./00 July 03

15 Technical Specification for Power Batteries for KAPS & Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet of R.0 SCOPE. This section covers the technical requirements for power batteries complete with battery racks, inter-cell connectors and all other accessories. Equipment offered shall strictly be designed for site ambient conditions described in project data..0 GENERAL. The equipment offered shall be complete with all parts that are necessary or usual for the efficient operation and maintenance of the equipment, whether specifically mentioned or not.. There shall be no impurities, harmful to the performance or life of the cells..3 The battery offered shall be of lead acid type, with tubular positive plates (TBS type). The battery shall be suitable for indoor installation in a clean and tropical atmosphere..4 The battery shall be designed to meet load requirements and other parameters indicated in the Data Sheets of Section: CC-3, till the end of life is reached. 3.0 CHARGING 3. Battery charging equipment provided will be capable of producing an output voltage which is suitably controllable for float, equalize and boost charging operation of battery with current limit provision, as stated in Section CC Float Charge Mode: During normal course of operation, the UPS will be connected to the load bus. The battery will receive a continuous charging current at constant voltage from the UPS at a low rate sufficient to compensate for internal losses during floating. Battery in this condition shall remain in a fully charged state. 3.. Equalizing Charge Mode: The battery will be given an equalizing charge as required during its life span, at constant voltage and current limit to correct any inequalities among cells of the battery that may develop during service. Supplier shall provide criteria and method of equalising charge. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

16 Technical Specification for Power Batteries for KAPS & Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS-& EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet of R 3..3 Boost Charging of the Battery: The boost charging will be carried out with the battery isolated from the bus and the battery will be boost charged by the battery charger. The boost charging cycle of battery may comprise of two stages: a) Initial charging: The charging of battery will be carried out at a voltage governed by the specified current limit. If the current drawn by the battery exceeds the set values of the current limit, the output voltage of the charger automatically reduces to ensure that the current limit is not exceeded. b) Final Charging: When the battery gets charged upto certain voltage, further charging may be carried out at reduced current set value for current limit. Subsequently charging of the battery would be at constant voltage. c) The intent of boost charging is that completely discharged battery after a C0 capacity test shall be capable of being fully charged with current limited at values indicated in Section CC-3. The battery offered shall meet this requirement. d) Further, the battery after a duty cycle discharge shall be capable of being recharged in 8 hours such that it is once again in a position to deliver specified currents due to second duty cycle discharge. The TENDERER shall specify in his offer the recommended duration of boost charging, method of boost charging, current limit etc 3..4 The values for battery charging voltage (per cell) indicated in this document are tentative. It is the responsibility of the TENDERER to furnish the voltages to be adopted for float, equalizing, and boost charging for PURCHASER`s consideration. The TENDERER shall give recommendations for charging requirements after duty cycle discharge and also, the charging requirements after C 0 discharge. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

17 Technical Specification for Power Batteries for KAPS & Volume II EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 3 of REVISION CAPACITY 4. The standard ampere-hour capacity of the battery bank shall be determined based on the latest edition of IEEE: 485 considering the requirement of duty cycle furnished in section CC-3 of this specification. The battery shall be capable of meeting its specified load cycle with additional 0% as design margin even at the end of life under the lowest specified site ambient conditions. Voltage drops across inter-cell connectors, inter-row terminals etc. shall be considered and the specified end of discharge voltage of the cell suitably increased so that bank voltages do not reach specified end of discharge voltage earlier. 4. TENDERER shall guarantee that the capacity of the battery offered by him is adequate for the duty specified. It may be assumed that the battery is charged to a state prior to the start of a fresh duty cycle as per charging requirement of Section: CC-3 and is discharged to an end cell voltage specified in Data Sheet of Section: CC-3, at the end of cycle. 4.3 Calculation and methodology adopt for arriving at the relevant C-0 capacity should be furnished along with the offer. In case of high rate discharge, a current vs discharge duration graph shall be enclosed so that battery may be high rate discharged at any other value for corresponding duration. The curve shall be validated to check its applicability. 4.4 The battery shall operate satisfactorily over the entire range of temperature indicated in the project data sheets. The TENDERER shall however, indicate, the percentage variation in battery capacity at 30 min. rate for power battery with variation in temperature from 08 C to 45 C with reference to the standard temperature of 7 C. 4.5 The battery shall be capable of duty cycle discharge at any time even after being kept under float charge for many months. 5.0 BATTERY LAYOUT Battery shall be complete with battery racks and should be mounted in single tier arrangement. BIDDERS should furnish dimensional drawings showing the proposed battery layout within the PURCHASER s battery rooms. Battery room dimensions are shown in the enclosed sketches as indicated in section CC-0 of this specification. The SPECIFICATION NO: KAPS/534/PB SEPC./00 July 03

18 Technical Specification for Power Batteries for KAPS & Volume II EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 4 of REVISION 0 battery layout should provide sufficient clearances from the walls and columns of the room. Each cell and connection of the battery bank shall be easily accessible for replacement/maintenance purposes. It shall be possible to easily carry out routine check for electrolyte level, specific gravity of electrolyte, temperature, terminal connections and measurement of individual battery terminal voltage. The PURCHASER envisages use of portable trolley for removal of individual cells. Sufficient space shall also be provided in between the rows to remove any cell using trolley. The installation shall conform to the requirement of the latest edition IEEE: LIFE The SUPPLIER shall state in his offer the expected design life of the battery as per site ambient condition in terms of: a) No. of calendar years from the date of commissioning. b) No. of charge, full C0 capacity discharges and duty cycle discharges under the maximum ambient conditions specified. 7.0 VENTILATION AND ROOM LAYOUT 7. The following ventilation arrangement is being provided by the PURCHASER. 7.. The battery rooms will be provided with exhaust fans to limit the hydrogen concentration to less than % by volume. Battery room temperature can be conservatively considered same as outside ambient. 7.. Bidder shall carefully study the battery room layout and indicate the number of air changes required in the battery room per hour so as to limit the amount of hydrogen in the battery room within permissible limit under severe condition of hydrogen emission. 7. Corrosion resistant lighting fixtures are provided in battery rooms. The TENDERER shall indicate special requirements (if any) for lighting. 7.3 Bidder shall clearly indicate any other special measures to be taken care of in the battery layout while submitting the technical offers. SPECIFICATION NO: KAPS/534/PB SEPC./00 July 03

19 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 5 of REVISION INTERCHANGEABILITY 8. All identical components and corresponding parts shall be fully interchangeable without having to carry out any modifications. 8. Components and parts that are not fully interchangeable are liable for rejection. CONTRACTOR shall replace all such equipment by fully interchangeable equipment at his cost 9.0 SEISMIC QUALIFICATION 9. Seismic Testing of Battery along with Stand V DC Power Batteries a) The Seismic design and qualification by test of station control batteries with all accessories including racks shall be as per IEEE: 344 on the basis of SSE (Safe Shutdown Earthquake Condition) and OBE (Operating Basis Earthquake) as per approved test procedure. b) The battery cells mounted on representative racks along with all accessories shall be designed and qualified by test to withstand without any malfunction or physical damage (either during or after the tests), the specified earthquakes, as defined by the enveloped required response spectra (will be furnished later to the successful bidder). These batteries shall safely withstand five (5) OBEs (Operating Basis Earthquake) followed by one () SSE (Safe Shutdown Earthquake). c) The TENDERER shall specifically confirm in his offer that the design of batteries, racks and all accessories meets the seismic requirement. Special attention of the TENDERER is drawn to the fact that the equipment cannot be accepted unless batteries with all accessories mounted are qualified by test to meet seismic requirements. 9.. If the TENDERER has already carried out tests on similar batteries with racks, and accessories, to meet the specified response spectra or for a more severe condition, the type test certificates for the same should be furnished. 9. Seismic Testing Co-ordination SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

20 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 6 of REVISION The seismic qualification of 354 V DC power batteries shall be carried out by actual testing in the shake table facility at the CPRI, Bangalore or at an equivalent facility. The testing shall be carried out in accordance with IEEE-344. The bidder shall indicate testing charges in their offer in Section: E. The testing charges payable to the testing agency will be reimbursed by the PURCHASER at actual after successful completion of testing. If the equipment fails to pass the seismic test due to deficiencies in design or manufacture or malfunctioning of test set up, the SUPPLIER shall bear such testing charges payable to test facility. The SUPPLIER shall be responsible for coordination with the testing agency for successful and timely completion of seismic testing. 9.. Safe transportation of the equipment to and from the Supplier's works to the testing laboratory, engineering and supply of materials required (for making base plates, base frames etc.) for mounting the equipment on shake table and required man-power are to be provided by the SUPPLIER. The SUPPLIER shall also arrange for various testing and measuring instruments (such as battery load bank, fast recorder, Megger, DC power supply rectifiers, storage oscilloscope etc.) required for these tests. A lump sum price for the above shall be quoted in Section: E of this specification under the heading of 'Seismic Testing Coordination Charges' In consultation with the PURCHASER and the testing agency, the SUPPLIER shall prepare a detailed testing procedure including the list of parameters to be monitored during the testing as well as the tests to be carried out on the batteries before, during and after the seismic test. The seismic testing procedure and acceptance criteria will be finalised after placement of P.O. As a minimum requirement, the following tests shall be included for the battery, battery racks. a) Visual inspection. b) Monitoring of current and voltage. c) Performance of C0 capacity test before and after the seismic test Seismic tested cells and stands shall not be supplied to PURCHASER. 9.3 All the Details of Seismic Response spectra for power battery room will be given to successful bidder. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

21 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 7 of REVISION CONSTRUCTIONAL FEATURES 0. Plates 0.. Tubular Positive Plates for Lead Acid Batteries Tubular positive plates as per IS-65:03 shall consist of suitable Gauntlet tubes with spines cast of suitable alloy of lead to give adequate mechanical strength suitable for prolonged float application, low electrical resistance, resistant to acid and oxidation. Acid resistant tubes (like terelene etc.) shall be inserted over each spine. After insertion, tubes shall be filled with adequate quantity of active material before their top ends are closed by a common bar. The construction and material of the tube shall be such that loss of active material is minimized during its service life and shall be able to withstand internal stresses developed during service. In case of antimonial alloy percentage of antimony added shall be indicated. 0.. Pasted Negative Plates for Lead Acid Batteries. The negative plates shall be of interlocking pasted grid design. The grids shall be cast with low antimony/calcium lead alloy and shall normally be of the box type. End negative plates, if of box type shall be of the half pasted type. Pasted plates shall have adequate mechanical strength and shall be so designed that the active material is maintained in intimate contact with the grid under normal working conditions throughout the life of the battery 0. Containers 0.. Containers of batteries shall be robust, heat resistant shock absorbing and shall have adequate mechanical strength to prevent bulging, cracking etc., during the life span of battery when operating under the specified temperature range including the temperature during full discharge and due to static and dynamic loads and the action of the electrolyte. The container should be of adequate size to have a large electrolyte reserve to give a topping up frequency of many months. The containers should safety withstand the effects of the specified seismic acceleration. 0.. The containers should be of Styrene Acrylonitrite (SAN) plastic, transparent and stress relieved with electrolyte level marking. The lids shall be moulded from SAN. The lid shall be properly bonded to the container. Supplier shall specify the relevant standards adopted for design and the test procedures for qualification for such type of container, in detail In order to prevent short circuiting of the plates, the container shall have adequate space at the bottom of the cell for collection of any sediment that might be shed from the plates during the life of the cell. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

22 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 8 of REVISION Vent Plug 0.3. The vent plug shall be of the micro porousantis plash flame arrestor type, preferably with more than one exit hole, and shall allow the gases to escape freely but shall effectively prevent electrolyte particles or spray from coming out even during boost changing. On removal, it shall permit drawing of the electrolyte samples. There shall be two vent holes, to permit drawing of electrolyte samples, checking of specific gravity etc. 0.4 Electrolyte Level Indicators 0.4. The maximum and minimum electrolyte levels shall be clearly marked on the outer portion of container on all four sides of transparent containers 0.4. The marking shall be in red colour and shall be oxidation proof and free from the action of electrolyte. 0.5 Separators 0.5. The separators shall be of acid resistant micro porous PVC or any other plastic or synthetic fibre based material suitably recognized and covered by internationally acceptable standard/is and shall have maximum electrolyte utilization and minimum internal resistance. The separator, shall maintain the electrical insulation between the plates and shall allow the electrolyte to permeate freely. The separator shall be dimensionally stable without deformation at operating temperature during full discharge. The separators shall be dimensionally stable without deformation at operating temperature during boost charging and shall posses chemical stability against electrolyte action. Separators, shall comply with the relevant standards mentioned in Section: CC Separator design and its assembly during cell manufacture shall ensure availability of sufficient space for passage of material shed by positive and negative plates. 0.6 Connectors 0.6. The inter-cell, inter-row, inter-bank connectors, complete with nuts, locknuts, bolts and washers shall be adequately designed to carry maximum short time duty cycle current and the steady state (charging) currents as specified and shall offer minimum impedance and low temperature rise during high rate of discharge. While considering the terminal voltage of the cell at the time of testing for discharge, the voltage drop due to inter bank, inter-row and inter-cell connectors shall be considered. Connectors shall be of lead plated electrolytic grade copper. The lead coating shall be adequate SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

23 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 9 of REVISION 0 and tenacious. Minimum thickness of lead coating shall be 75 microns. Connectors shall be adequately designed to withstand various stresses due to temperature changes, attack of electrolyte and dynamic forces including seismic forces that could occur during the operation of the battery. Connectors shall be provided with insulated covers. Stranded flexible copper conductor (Class-V as per IS:830) cable insulated with unvarnished fibre-glass sleeves (or rubber insulation) shall be provided for all interconnections between cells of adjacent stands where flexibility is required. Insulation shall withstand a power frequency voltage of.0 kv for min. 0.7 Terminal Posts 0.7. The positive and negative terminal posts of the cells shall be clearly and unmistakably identified. Terminal posts shall be designed to accommodate external bolted connection conveniently and positively and cause minimum voltage drop and minimum temperature rise even during high rate of discharge of the battery. Adequacy of standard cell terminals for specified high rate of discharge shall be checked and confirmed. Bolt-heads and nuts, except seal nuts, shall be hexagonal and shall be lead coated and head will be insulated (like ABS insulation). The junction between terminal posts and cover shall be so sealed as to prevent any seepage of electrolyte. All the cells shall be pressure tested to check the seal. Terminal posts shall be adequately fixed to prevent its turning or twisting when the connections are being fixed or removed If required, lead alloy terminal posts with copper or brass insert/fillers shall be provided. Copper inserts shall be properly centered and adequately covered with lead so as to avoid its direct contact with acid. 0.8 Group Bars 0.8. The group bars shall be made of fully paralleling bars on the positive and negative groups, ensuring that the plate lugs are firmly burnt into the group bars. The manufacturing process shall be controlled to achieve minimum voltage drop, adequate mechanical strength throughout their life and shall be performed by qualified workmen based on a qualified procedure. 0.9 Electrolyte 0.9. The electrolyte for lead acid cells shall be battery grade sulphuric acid conforming to latest editions of IS-66. Required quantity of electrolyte for first filling shall be supplied in non- returnable, acid resistant containers. Specific gravity of the electrolyte shall be indicated on the container. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

24 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet 0 of REVISION Water Water used for preparation of electrolyte and also to bring the level of electrolyte to approximately correct height during operation/testing shall conform to the latest edition of IS: Termination Facility for PURCHASER's Connections. 0.. The battery terminals shall be brought upto a flat terminal plate. Insulated barriers shall be placed between the positive and negative terminals. PURCHASER's cable or bus duct for positive and negative terminals will be terminated with lugs. Size of cables or bus bars will be indicated to successful bidder. The terminal plate shall be suitable for operating in acidic atmospheres. Suitable supporting insulator shall be provided for the terminal plates. The supporting arrangement should safely withstand short circuit forces and seismic forces. Bolts with nuts, check nuts and spring washers shall be provided for connecting to PURCHASER s cable lugs or flexible copper terminals..0 Accessories for Testing & Maintenance. Each lead-acid battery bank shall be complete with all accessories and devices, including, if required insulating pads for battery racks and cells.. Each cell, should have a permanent label indicating the cell number..3 Suitable set of insulated spanners..4 A portable trolley with swivel type wheels of adequate size for the installation and removal of individual cells. If required, to suit the layout the platform of the trolley should be adjustable.5 Cable clamps with hardware for supporting outgoing cables on battery..0 BATTERY RACKS. a) Battery racks for lead acid cells shall be constructed from MS structure sections and painted with two coats of approved acid resisting paint or FRP coating on the stand. The racks shall be rigid, free standing type and free from warp and twist. The completed racks shall be suitable for bolting end to end to form a continuous row. Insulating pads may be provided below the legs racks as well as below the SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

25 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet of REVISION 0 cells. In case of steel stands, suitable neoprene rubber strips shall be placed on stand members to provide packing and electrical insulation between stand and sides of cells. Bottom of cells shall also be placed on suitable insulating material for mounting. b) Battery rack shall be of adequate strength to meet all static and dynamic loading. c) Steel stands shall undergo suitable pre-treatment process before application of paint or shall be subjected to approved shot blasting techniques to remove rust before painting. d) Provision shall be made to connect the metal racks to the Purchaser's earthing system. e) Typical layout of battery racks shall be submitted along with the offer.. Each battery room is provided with EPs flushed with the floor The battery stand shall be welded to the base EPs to make the complete battery bank supporting arrangement rigid. Typical fixing arrangements of the stand to the floor will be furnished to the successful bidder. 3.0 TRAINING REQUIREMENT: Operational & maintenance training of the supplied battery type shall be provided to 0 (Twenty) technicians/supervisors/engineer of KAPS at KAPS site. This training course shall be approved by PURCHASER. Training period shall be minimum of two day. Following aspects shall be covered in the training: Battery specifications. Battery type and constructional details. Daily, Weekly & Monthly routines required on battery cells. Recommended charging methods and various charging requirements for the battery. Limitations and DOS & DONTS for the battery. Battery equalizing charging and Load tests (C-0 & HRD) and recommended rate of discharge, frequency and procedure. Acceptable battery parameters ranges and action in case any abnormality such as electrolyte specific gravity, level & temp, Voltage levels. Failure history and/or history of similar type batteries in industry. Various failure mechanism and trouble shooting chart for supplied battery type. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

26 Technical Specification for Power Batteries for KAPS-&. EQUIPMENT CONSTRUCTION AND DESIGN DETAILS Section: CC-4 Sheet of REVISION 0 To & Fro transport charges, boarding & loading charges of the suppliers faculty and the training material etc. cost will be borne by the supplier. Training charges, if any shall be mentioned in the offer. If training is free the same shall be mentioned in the offer clearly. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

27 Technical Specification for Power Batteries for KAPS- &. Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS- &. INSPECTION AND TESTING Section: CC-5 Sheet of 8 R.0 The equipment covered by this contract shall be subjected to inspection and testing. The SUPPLIER shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-CONTRACTORS to ensure the mechanical / electrical performance of components, compliance with drawings, identification and acceptability of all materials, parts and equipment..0 The SUPPLIER shall perform his internal inspection / testing before offering the equipment for PURCHASER's inspection. Only after ensuring that his inspection / test results are satisfactory, SUPPLIER shall offer the equipment for PURCHASER's inspection. However this clause is not applicable in case of such tests which are required to be done only once in the life time of the equipment. 3.0 The minimum inspection requirements for all components/equipment shall conform to the design and fabrication requirements as defined in the codes and standards referred to in the specification document. The type of inspection shall be as prescribed in quality control plan and as agreed upon by the PURCHASER, and shall include, if applicable, inspection procedures prescribed by codes and regulations recognized by the Governmental Authority having jurisdiction over the installed goods. 4.0 Wherever required, getting approval of Government bodies under jurisdiction is the sole responsibility of SUPPLIER for his design, drawings, manufacturing, testing and inspection by such bodies. In such cases approval by Government bodies under jurisdiction will not relieve the SUPPLIER from his responsibility of making good of defective material/equipment/system. However, SUPPLIER shall keep the PURCHASER/his representatives informed in writing of any approval or otherwise any comments of such Government bodies. SUPPLIER shall take the concurrence of PURCHASER or his representative before proceeding with rectification procedures as called by the Government bodies. 5.0 Approval or passing of any such inspection by the PURCHASER or his authorized representative shall not, however, prejudice the right of the PURCHASER to reject the equipment if it does not comply with the specification when erected or give complete satisfaction in service. 6.0 The SUPPLIER shall intimate the PURCHASER well in advance of any material being ready for testing. Such tests shall be to the SUPPLIER's account except for the PURCHASER's expenses. The PURCHASER or his representative, unless the inspection of the tests is virtually waived, shall witness such tests on a mutually agreed date. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

28 Technical Specification for Power Batteries for KAPS- &. Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS- &. INSPECTION AND TESTING Section: CC-5 Sheet of 8 R 7.0 The PURCHASER shall give notice in writing to the SUPPLIER of any objection to any drawings and, all or any equipment and workmanship which in his opinion is not in accordance with the 'Contract'. The SUPPLIER shall give due consideration to such objections and shall either make the modifications that May be necessary to meet the said objections or shall confirm in writing to the PURCHASER giving reasons therein that no modifications are necessary to comply with the 'Contract'. However, PURCHASER has the final authority to accept or reject the SUPPLIER's views. The equipment / material after rectification by the SUPPLIER shall be offered to the PURCHASER for his final inspection and acceptance without any additional cost to PURCHASER. 8.0 When the factory tests have been completed at the SUPPLIER's or his SUB- CONTRACTOR's works to the satisfaction of the PURCHASER, the PURCHASER shall issue a certificate to this effect within fifteen (5) days after completion of tests, but if the tests are not witnessed by the PURCHASER's representative, the certificate shall be issued within fifteen (5) days of the receipt of the SUPPLIER's test certificate by the PURCHASER provided the test results are satisfactory and conform to the specified parameters. The completion of these tests or the issue of the certificate shall not bind the PURCHASER to accept the equipment should it, on further tests after erection, be found not to comply with the 'Contract'. 9.0 In all cases where the 'Contract' provides for tests whether at the premises or works of the SUPPLIER or of any SUB-CONTRACTOR, the SUPPLIER, except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the PURCHASER or his authorized representative to carry out effectively, such tests of the equipment in accordance with the 'Contract' and shall give facilities to the PURCHASER or to his authorized representative to accomplish testing. 0.0 The inspection by the PURCHASER and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the SUPPLIER in respect of agreed quality assurance programme forming a part of the 'Contract'..0 In the case of stage inspection, the SUPPLIER shall proceed from one stage to another only after the component is inspected by the PURCHASER or his representative and permission given to proceed further. The same procedure shall be adopted for any rectifications / repairs suggested by the SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05

29 Technical Specification for Power Batteries for KAPS- &. Kakrapar Atomic Power Station Unit & Technical Specification For Power Batteries for KAPS- &. INSPECTION AND TESTING Section: CC-5 Sheet 3 of 8 R PURCHASER or his representative. At all Customer hold points the SUPPLIER shall compulsorily offer for inspection to PURCHASER and, if any waiver by PURCHASER shall be obtained in writing for record purposes..0 None of the equipment to be furnished or used in connection with the contract shall be dispatched until shop inspection, satisfactory to the PURCHASER or his representative has been made and specific Dispatch Instructions for the equipment is issued by the PURCHASER. However, such shop inspection shall not relieve the SUPPLIER of his responsibility for furnishing the equipment conforming to the requirement of the contract nor prejudice any claim, right or privilege which the PURCHASER or his representative may have because of the use of defective or unsatisfactory items of the equipment. Should the PURCHASER or his representative waive the right to inspect any item of the equipment, such waiver shall not relieve the SUPPLIER in any way from his obligation under the contract. In the event of the PURCHASER on inspection revealing poor quality of goods, the PURCHASER or his representative shall be at liberty to specify additional inspection procedures, if required, to ascertain the SUPPLIER's compliance with the equipment specifications. 3.0 All principal mill test reports, test certificates and test curves shall be supplied for all tests carried out including other records such as stress relieving charts, radiographic charts and other non-destructive testing records in accordance with the provisions of the contract. The PURCHASER or his representative shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture. 4.0 SUB-ORDERS 4. To ensure getting good quality product from SUB-CONTRACTOR, the main SUPPLIER shall get the approval of PURCHASER by furnishing details of capability, experience, manpower, manufacturing facility, quality control facilities etc. of the SUB- SUPPLIERS before placement of order. The PURCHASER may visit the SUB-SUPPLIER's works to evaluate their capacity and capability to do quality job to meet specification requirements. The sub-orders should highlight the inspection and quality control requirements stipulated in the main specification and all required quality checks and tests shall be conducted as per the specification. SPECIFICATION NO: KAPS/534/PB SEPC./00 Oct-05