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CONTENTS
1
1.1
1.2
GENERAL......................................................................................................................
Drawings..........................................................................................................................
Equipment Identification and Color Codes.......................................................................
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
TECHNICAL DESCRIPTION......................................................................................
General Requirements.......................................................................................................
Battery..............................................................................................................................
Battery Charger.................................................................................................................
General.............................................................................................................................6
Design Details...................................................................................................................7
Charger Construction........................................................................................................8
Instrumentation and Control.............................................................................................9
Sound Control.................................................................................................................11
Nameplates, Labels and Markings..................................................................................11
Painting/Corrosion Protection.........................................................................................11
3
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.3.1
3.3.2
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GENERAL
This specification covers the design, manufacture, factory testing, marking, packing, shipping,
transportation to site, installation, site testing and commissioning of 48V battery and charger.
The detailed and specific data are specified in the Drawings, Technical Data Sheets and other
documents that form part of this Specification.
The required batteries and chargers shall conform in every respect to international recognised
standards of engineering design and workmanship and shall be capable of performing continuous
commercial operation within the parameters guaranteed by the manufacturers and in accordance
with the specifications.
The batteries and chargers, to be offered, shall be complete in all respects necessary for their
effective and trouble free operation as far as possible.
For applicable technical standards, tests and general requirements, reference shall be made to
Standard Technical Specification, Part:
S-AA-AUX-GEN
1.1
Drawings
Typical drawings for Substation Supply systems provided in the Drawings Section are as
follows:
Drawing No.
Title
ADWEA AUX 02 03
1.2
Concerning batteries and chargers identification, reference shall be made to Standard Technical
Specification, Part:
S-AA-GEN-ID
Components Marking
TECHNICAL DESCRIPTION
2.1
General Requirements
The 48V DC battery/charger system shall be used in the 11 kV, 33 kV Prefabricated Stations,
11/0.4 kV distribution Stations and 11 kV or 33 kV Switching Stations to provide the required
DC supply for the protection equipment, local indications, control, communication, etc.
The charger to be offered shall be of the modular compact type and shall preferably be
accommodated together with its VCU & distribution board in one cubicle.
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One voltage control unit (VCU) for regulating the DC output voltage at the 48V
distribution boards when the rectifier/chargers are in float/trickle or boost charge mode
The required battery/charger system shall be rated/designed such as each rectifier module can
cater for 100% of the entire calculated DC load including the planned extension of the Substation
at the final stage. The calculation shall be provided upon approval of all equipment, and after the
details of its maximum consumption have become known, which shall eventually form the DC
load. Both charger modules shall, continuously be feeding the entire load on sharing basis
through a common output. However if either of the modules goes out of service due to any
reason, the other module shall be able to feed the full load and there should not be any
interruption in the DC supply.
The nominal rating of the DC supply shall be 48V at DC Distribution Board Busbar.
The DC voltage at the remote DC load point (that has to be established by the Contractor as per
SS layout) shall neither drop in any event below 90% of its nominal value after the battery has
reached its end of discharge (taken the full emergency load for 10 hrs.) nor exceed 105% of the
nominal value during boost or float/trickle charge.
The charger shall be fed separately by either 230V, single phase, 50 Hz or 400V AC, 3-phase
system, 50 Hz. The required MCB at the AC distribution board as well as the wiring and power
cables shall be included.
In the normal operation, the charger modules shall be operating either in float charge or boost
charge mode, and through the common output shall be charging the battery as well as feeding via
the VCU, the connected load.
In the case of failure of either of charger modules, the other module shall provide the entire DC
load. Whereas, in the case of complete charger failure, the battery alone shall be feeding the
connected load for the specified time (10 hrs).
The batteries and chargers shall be sized to provide the DC load 10 hrs, taking into consideration
the following:
Two tripping operations on all circuit breakers in the station, with simultaneous
tripping of all circuit breakers on any one bus-bar of each switchboard.
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2.2
Battery
The battery cells shall be connected in series/parallel such as to form the required battery bank
that provides the required terminal voltage as specified and to cater for the voltage drop when the
battery is feeding the DC load alone (charger is disconnected).
The 48V battery to be offered shall be of the Lead Acid type of low discharge rate application
and shall be rated/designed to work at the maximum ambient temperature of 50 0C in the
prevailing site conditions specified in Technical Specification, Part:
S-AA-GEN-GDF
- General Conditions
Battery bank shall be formed from single cells in order to achieve cost effective maintenance
services.
The normal service life of the required battery shall not be less than 25 years, without severe
adverse effect due to the prevailing ambient temperature conditions.
The complete details of the required battery cells are given in the technical data sheets of this
specification.
The battery cells shall be supplied together with the required quantity of electrolyte for the initial
filling at site.
The electrolyte performance and the design of the cells shall be such that the time intervals
between successive site inspection and routine maintenance activities, including topping up of
the electrolyte, are not short, (not shorter than six months).
The following information shall be indelibly marked on outside of each cell of the batteries:
a)
b)
c)
Ah capacity.
d)
At site each battery cell, upon mounting the entire cells on the battery stand, shall be numbered
in a sequence subject to approval by ADDC/AADC.
The Bidder/Contractor may furnish any additional technical particulars relevant to the
technology of the battery offered in addition to the specified technical particulars.
Earth leakage relay, which shall operate in the event of earth leakage current, has to be provided.
It shall be possible to easily disconnect the battery earthing.
Protection shall be provided to cater for the over discharge or short circuit incidents of the
battery.
The battery shall be mounted on steel stands of robust construction. The stands shall be treated
with acid resisting enamel or glossy paint and the cells shall be arranged in the tiers so that each
cell is readily accessible during site tests or inspection.
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The stands shall be mounted on insulators and be so dimensioned that the bottom of the lower
tier is not less than 300mm above the floor.
The comp1ete mounting shall be placed in a well-ventilated environment in the respective
substation.
Battery shall be supplied and erected complete with all necessary connections and cabling.
Connections between the tiers or between the end cells shall be by PVC cables arranged on
suitable racking or supports.
The connections between the cells shall preferably be bolted type. The bolts and nuts, the
connectors, etc. shall be effectively lead-coated to prevent corrosion.
Terminal plates of each cell shall be clearly marked as positive and negative. End take-off
connections shall be made by single core PVC insulated cables.
A box (made of galvanised steel and suitably painted to match other installations in the same
vicinity) equipped with a set of fused switch disconnectors together with auxiliary alarm contacts
for remote supervision shall be mounted close to the battery. The number and arrangement of the
fused switch disconnectors shall be such as to enable disconnection of the battery without
interrupting the supply from the charger to the load and also to enable disconnection of the
charger output without interrupting the supply from the battery to the load through the VCU.
Warning signs shall be fitted to precaution personnel of the danger of removing or replacing a
fuse whilst the load is connected.
It shall be possible to monitor the operation of the fused switch disconnectors when
disconnecting the battery from the system either for maintenance or due to faults.
One set of tools comprising two syringe hydrometers, one voltmeter, ten cell-bridging
connectors, one electrolyte-pouring funnels, two electrolyte thermometers, battery instruction
card for wall mounting, electrolyte airtight containers, labels, other items necessary for the
erection and correct functioning and maintenance of the battery shall be provided with the
battery.
2.3
Battery Charger
2.3.1
General
For battery charger, VCU and DC board cubicle requirements, reference shall be made to
Standard Technical Specification, Part:
S-AA-CUB
The operational characteristic of the charger shall be in accordance with DIN 41772 and DIN
41773.
The battery charger and its Voltage Control Unit (VCU) shall be of the modular constant voltage,
constant current type.
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The battery charger shall be capable of continuous operation at the respective rated load,
charging the battery, either on float or boost charging modes, at the voltage per cell while
supplying the DC load through the distribution board.
2.3.2
Design Details
The input of the charger shall be equipped with a device, which shall cause the charger to switch
off in the event of DC output over voltage.
AC and DC switches shall be provided at the input and output with the adequate rating
correspondingly. The operating handle of the switch shall be fully insulated. Rating of switches
shall suitable for their continuous load. Switches shall be fully protected by associated high
rupturing capacity fuses during abnormal operating conditions such as short circuit etc.
The charger failure device shall detect the AC supply voltage failure. The detecting device shall
not operate on switching surges or transient loss of voltage due to faults on the power system. In
addition, the charger shall be equipped with an MCB at the input and fuses and an off load
isolator at the DC output.
The battery charger shall be provided with facility for both automatic and manual control of
output voltage and current.
The battery charger shall have current limiting facility, which, if the voltage control is in
automatic mode, shall cause a gradual lowering of the output voltage when the DC load current
exceeds the load limiting setting of the charger. The current limiting characteristics shall be such
that any overload or short circuit in the DC system shall neither damage the charger, nor cause
blowing of any of the charger fuses. The charger shall not trip on overload or external short
circuit. Soft start feature should be invariably provided to minimize the in-rush current from the
float charger to discharged battery.
Uniform and smooth adjustments of voltage setting (in both manual and automatic modes) shall
be provided on the front of the charger panel. During boost charging, the battery charger shall
operate on constant current mode (when automatic regulator is in service). It shall be possible to
adjust the boost charging current continuously over a range of 50 to 100% of the rated output
current for boost mode.
The charger output voltage shall automatically go on rising, when it is operating on boost mode,
as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be
provided, whereby it shall be possible to set the upper limit of the boost voltage as per the
specified value.
The charger shall automatically switch into the equalizing/boosting mode when the battery has
discharged to a pre-set value. A timer to control the boost charging time shall be provided.
The charger shall be able to recharge a fully discharged battery from the end cell voltage to 95%
of its capacity within a time interval of not more than 10 hrs and in the mean time supply the
equipment design load.
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Suitable filter circuits shall be provided in the charger to reduce as much as possible the ripple
content and also to suppress noise in the output voltage irrespective of the DC load, especially
when the battery is not connected to the charger. The charger output voltage (battery
disconnected from the charger) shall be free from the noise, (not more than 5 mV,
physometrically weighed. The interference voltage, frequency evaluated, shall not exceed 2 mV
at 60V units as per the ITU-T.
The design of the charger shall be such that when the battery is disconnected, the output voltage
shall be maintained within the specified limits as if the battery is in the system.
Short circuit at the charger output shall not cause any damage to the charger.
The construction of the charger shall be such that access to all components is readily available
for maintenance removal, or replacement.
A thermal overload relay incorporating a distinct single phasing protection shall be provided for
the AC input. The relay shall trip the input AC contactor.
The rectifier transformer shall be copper wound and continuously rated natural air-cooled type.
AC and DC Voltmeters and Ammeters (with shunt) shall be provided for the charger/distribution
board, at the input and output correspondingly. The instruments shall be flush type, dust proof
and moisture resistant. The instruments shall have easily accessible means for zero adjustment.
All fuses shall be of the HRC type with auxiliary alarm contacts for remote supervision.
Fuses shall be mounted on fuse holders, which in turn, are mounted on fuse bases. However, if it
is not possible to mount fuses on holders, they may be directly mounted on plug-in type base. In
such cases one insulated fuse pulling handle shall be supplied for each charger. Fuse rating shall
be chosen such as to cater for the protection purpose associated with, which shall be subjected to
the approval of ADDC/AADC.
The blocking diodes shall be provided at the charger output in such a way to prevent any reverse
current flow from the DC battery into the charger.
2.3.3
Charger Construction
The battery, battery charger and DC distribution panel shall be installed in an indoor, floormounted, self-supporting sheet metal enclosed cubicle.
The DC distribution panel shall incorporate double-pole switches, with auxiliary contact for
alarming in the case of tripping/switching off, for each of the outgoing DC circuits and doublepole isolators for the incoming DC supply from the charger and for the battery connections. The
panel shall be provided with a voltmeter and centre zero ammeter.
Where necessary, over voltage detection equipment shall be included to isolate the AC supply to
the chargers when the output voltage exceeds the specified high limit.
A time delay shall be incorporated to prevent operation when a battery with high open circuit
voltage is switched from the boost to float condition.
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The Bidder/Contractor shall supply all necessary base frames, anchor bolts and hardware. The
housing shall be fabricated from cold rolled sheet steel and shall have folded type of
construction. Removable gland plates shall be part of the charger/distribution panel. The lugs for
power cables shall be made of electrolytic copper with tin coat. Power cable sizes shall be
defined based on calculation for the voltage drop over each stage and accordingly the suitable
cable lugs and drilling of gland plates can be defined.
The housing shall be tropicalised and vermin proof. Ventilation louvers if provided shall be
backed with screens. All doors and covers shall be fitted with synthetic rubber gaskets.
The housing shall have hinged double leaf doors at the front and at the backside i.e. charger
housing shall have both front and rear end openings for adequate access to the charger interior.
Charger cubicle doors shall be properly earthed. The degree of protection of charger cubicle shall
be at least IP-42.
All indicating instruments, control switches and indicating lamps shall be mounted on the front
side of the housing.
The control wiring shall be carried out with PVC insulated, of at least 2.5 mm 2 stranded copper
wires. Control terminals shall be suitable for connecting two wires, with 2.5 mm 2 stranded
copper conductors. All terminals shall be numbered for ease of connections and identification.
Each wire shall bear a ferrule or tag on each end for identification. At least 20% spare terminals
shall be provided for control circuits.
The insulation of all circuits except the low voltage electronic circuits shall withstand test
voltage of 2 kV AC for one minute. An air clearance of at least 10mm shall be maintained
throughout for such circuits, right up to the terminal lugs. Whenever this clearance is not
available, the live parts shall be insulated or shrouded.
2.3.4
b)
c)
d)
Three dc voltmeters with suppressed zero (one for the charger output, one for the battery
voltage and one for the load voltage).
e)
Three dc ammeter, (one for the charger output current, one for the battery current bidirectional and one for the load current) with internally-mounted shunt if charger output
exceeds 50 amperes.
f)
g)
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h)
Potentiometer for adjusting d-c output voltage (in MANUAL position) with the ranges of
positions necessary to set the charger from "float charge" to "equalizing charge".
i)
A timer with a range of 0 to 24 hours to control the equalizing period. The timer shall
automatically be activated upon restoration of AC supply voltage following the loss of AC
input power.
AC supply on
AC supply fail
Rectifier failure
DC output high
DC output low
Charger on boost
Battery Ah available.
Charger shall be self-protected against high transient over-voltages in dc and ac control and
power circuits. This protection shall be built into the equipment and no special external
connections, configuration of leads or connections of any external equipment shall be
required.
b)
AC input thermal magnetic air circuit breaker (number of poles and interrupting capacity
in accordance with system requirements).
c)
Protection against discharge of the battery into the battery chargers upon failure of the AC
supply, with automatic resumption of pre-set charging rate when power is restored.
d)
e)
f)
DC over-voltage relay.
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g)
Any failure of the charger, detected by any of these alarms, or protective devices shall be
indicated locally, either by lights, or on the front of the rectifier and on local annunciation
panel. These alarms shall be possible for grouping in one common alarm for remote
transmission.
h)
Forced air cooling system failure alarm shall be provided if such a cooling system is used.
i)
2.3.5
Sound Control
The level of the sound generated by the charger/VCU equipment, which is supplied under this
specification, shall meet requirements as specified in the Technical Data Sheets.
In case the maximum level of the sound exceeds the specified allowable value (see Technical
data sheets), the Bidder/Contractor shall use acoustical treatment features, subject to
ADDC/AADC's review and acceptance, to achieve the sound control design objectives.
2.3.6
The nameplates shall be white with black engraved letters. On top of each battery bank, charger,
on front as well as rear sides, larger and bold nameplates shall be provided to identify the
charger. Nameplates with full and clear inscription shall also be provided on and inside of the
panels for identification of the various equipment and ease of operation and maintenance.
2.3.7
Painting/Corrosion Protection
For Corrosion Protection measures, reference shall be made to Standard Technical Specification,
Part:
S-AA-CORR
Corrosion Protection
3.1
General
Testing of the battery and charger shall be performed in line with this specification and in
accordance with the relevant IEC Standards (as minimum requirement) and other Standards as
may be approved by ADDC/AADC.
The battery and charger system shall be subject to inspection and test by ADDC/AADCs
engineers.
Acceptance by ADDC/AADCs representative of any unit shall not relieve the manufacturer
from any of his performance guarantees or from any other obligations.
Test certificates for each unit shall be submitted prior to delivery of the unit.
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ADDC/AADC reserve the right to perform checks during manufacturing process at any time or
all the times. It shall be at the discretion of ADDC/AADC to witness tests on 100%, or any
percentage quantity of each lot for routine tests, apart from the type tests, wherever called for.
Testing of the battery charger system shall include the factory and site tests.
3.2
Factory Tests
3.2.1
Type Tests
The battery and charger system/equipment shall be fully type tested. These tests shall include all
type tests as defined in the relevant latest IEC recommendation (as a minimum requirement).
Evidence shall be given that the battery and charger together with the VCU to be provided, under
these specifications, have successfully passed all type tests of design, service frequency, impulse,
insulation level, dynamic operating range, and electrical and mechanical endurance performance,
as appropriate and as specified.
However, if deemed necessary, ADDC/AADC shall decide if additional tests are required to be
performed by the Bidder/Contractor.
The Bidder/Contractor shall supply certified copies of type test certificates covering the
proposed battery charger system of similar/higher rating, operating range, data features, design
and construction.
An internationally recognised laboratory shall certify the type test reports.
Type tests certificates/reports shall be considered acceptable if they are in compliance with the
relevant Standards and the following:
1. Type Tests conducted at an internationally recognised laboratory acceptable to
ADDC/AADC.
2. Type Tests conducted at the manufacturers laboratory and witnessed by representatives from
an internationally recognised laboratory acceptable to ADDC/AADC.
If the presented type test reports are not in accordance with the above requirements,
ADDC/AADC may decide to ask for the type tests to be carried out in the manufacturers
premises or other places subject to the approval of ADDC/AADC at no additional cost, and in
the presence of an internationally recognised laboratory who should issue the relevant type test
certificates upon successful test.
3.2.2
Sample Tests
Functional tests.
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3.2.3
Routine Tests
The Bidder/Contractor is required to carry out routine tests on each assembled and finished
battery & charger system to demonstrate the integrity of the DC supply system.
Routine test certificates shall be submitted for ADDC/AADCs review and approval before
shipment of the battery & charger.
The battery & charger shall pass all the routine tests as laid down in the relevant IEC Standards.
The visual Inspection, which shall determine conformity of the battery & charger equipment with
the requirement, shall be part of the routine tests. In addition to the standard routine tests on the
charger, the following tests shall be performed:
Load test
Insulation test
3.2.4
Special Tests
The following tests shall be carried out in addition to what has been stipulated in the IEC
Standard:
3.3
Site Tests
Upon installation of the battery and battery charger, system they shall be tested in the presence of
ADDC/AADC engineers or their representatives.
The site tests shall comprise but not limited to the following tests:
3.3.1
Battery Charger
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b) Checking of main breaker trip element dimensions and ratings at the battery charger cabinet
shall be performed and comparison with the ADDC/AADCs elementary wiring diagram
drawings.
c) Checking the operation of the main breaker by application open-close-open sequence
manually.
d) Checking of wiring termination and conductor sizes.
e) Checking of levelling and alignment of installed battery charger cabinets.
f) Checking of tightness of connections and fastenings, and use of proper tools.
g) Checking the correct phasing of equipment connections.
h) Checking the proper grounding.
i) Checking of all current carrying connections, including bus connections and wiring, as
installed by Bidder/Contractor, in agreement with wiring drawings.
j) Checking of physical integrity of major parts and all instruments and components.
k) Checking of proper battery charger cabinet and cable identification.
l) Checking the correct circuit fusing.
m) Checking the ratings, dimensions, protection class of all major components, as panels,
cubicles, silicon rectifiers, buses, circuit breaker, fuses, relays, transformers, etc. and
confirmation that the equipment complies with the specification. Any non-compliance shall
be reported to the Contracting Officer.
3.3.1.2 Tests
a) Polarity check.
b) Battery voltage check.
c) Proper settings and calibrations.
d) Meter calibration and operation.
e) Functional check of all alarm circuits including low voltage, ground detection and AC
failure.
f) Insulation resistance test.
g) Output ripple test.
h) The ability of the charger to maintain this desired operating voltage level.
i) Testing of breaker trip settings.
j) Measurement the continuity of each current carrying connections by MEGGER.
k) Testing the changing output voltage function by disconnected battery.
l) Testing the quick charge and trickle charge mode.
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Battery
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