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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 1 of 13

BATTERY AND BATTERY CHARGER

Document No: G3IR-1050-65-SP-9037

Unit: Discipline: Document Type:

General Electrical Specification

Document Title: SPECIFICATION FOR BATTERY AND BATTERY CHARGER

DISCLAIMER
THIS DOCUMENT DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS DOCUMENT CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.

ISSUED FOR DESIGN


08 Aug 2012

1 0 Revision

30-Jul-12 19-Jul-12 Date

Issued for Design Issued for RFQ Purpose

RR RR Prepared By

NG NG Checked By

VP VP Fluor BASF Approved By

G3IR-1050-65-SP-9037_R0

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 2 of 13

BATTERY AND BATTERY CHARGER Record of Revisions This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 1 Date Description

19-Jun-12 30-Jul-12

Issued for RFQ Issued for Design

G3IR-1050-65-SP-9037_R0

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 3 of 13

BATTERY AND BATTERY CHARGER

TABLE OF CONTENTS
1.0 1.1 1.2 1.3 1.4 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 GENERAL .................................................................................................................................................. 4 Scope......................................................................................................................................................... 4 References ................................................................................................................................................ 4 Service Conditions................................................................................................................................... 5 Reliability /Availability.............................................................................................................................. 6 TECHNICAL REQUIREMENTS ................................................................................................................ 6 General ...................................................................................................................................................... 6 Design Criteria.......................................................................................................................................... 6 Rectifier ..................................................................................................................................................... 7 Internal DC Distribution Board ............................................................................................................... 7 Control and Instrumentation................................................................................................................... 8 Battery ....................................................................................................................................................... 9 Battery Support ........................................................................................................................................ 9 Battery Disconnector ............................................................................................................................... 9 Battery Accessories............................................................................................................................... 10

2.10 Equipment enclosure............................................................................................................................. 10 2.11 Painting and Finishing........................................................................................................................... 11 2.12 Equipment Identification ....................................................................................................................... 11 2.13 Noise........................................................................................................................................................ 11 3.0 4.0 5.0 INSPECTION AND TESTS ...................................................................................................................... 11 SPARE PARTS........................................................................................................................................ 13 DRAWINGS AND DOCUMENTS ............................................................................................................ 13

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 4 of 13

BATTERY AND BATTERY CHARGER 1.0 GENERAL 1.1 Scope 1.1.1 This specification is intended to cover design, engineering, procurement,

manufacture, inspection and testing at manufacturers works, packing, loading, forwarding, transport and delivery to site, erection / installation, testing and commissioning at site of DC SUPPLY SYSTEM. 1.1.2 The equipment shall be complete manufactured assembly consisting of enclosure, battery charger, batteries, switching elements, DCDB and other items as described in the subsequent part of specification and data sheets that form part of the material 1.1.3 1.1.4 Seller shall furnish any special tools required for installation and maintenance. Supplier is required to carefully examine and understand the specifications and seek clarifications, if required, to ensure that he has understood the specifications as intended by the Owner. In the absence of any specific clarifications made by the Supplier during bidding stage, the interpretation of Owner shall be final. The Suppliers offer should not carry any sections like clarifications, interpretations and/or assumptions. All such points are required to be clarified during bidding stage. 1.1.5 The Supplier may also make alternate offer provided such offers are superior in his opinion, in which case, adequate technical information and justifications, operating feed back data etc. shall be enclosed with the offer, to enable the Owner to assess the superiority and reliability of the alternative offered without the need to seek any further clarification or explanation. In case of each alternative offer, its implications on the performance and definite advantages shall all be clearly brought out along with commercial implications, if any, for the Owner to make an overall assessment. In any case, the base offer shall necessarily be in line with this specification. An alternative offer without the base offer as per the specification shall not be considered. 1.2 References 1.2.1 The DC SUPPLY SYSTEM and its associated auxiliary equipment shall conform to the latest editions of following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified. Each publication shall be the latest revision and

addendum in effect on the date this specification is issued for Purchase, unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, as a minimum, Work included in this specification shall conform to the applicable provisions of these publications.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 5 of 13

BATTERY AND BATTERY CHARGER S.No. 1 2 3 4 5 6 7 8 9 10 11 1.2.2 Description Direct acting indicating analogue electrical measuring instruments and their accessories Code of designation of semi- conductor devices Guide for preparation of drawings for semiconductor devices and integrated circuits ( part 1-2 ) Code for practice for the use of semi- conductor junction Low-voltage fuses for voltages not exceeding 1000V AC or 1500 V DC Stationary cells and batteries, lead-acid type with plante positive plates Safety code or semi-conductor rectifier equipment Stabilized Power supplies DC output ( part 1-4) Semi- conductor devices discrete devices and integrated Circuits Low voltage switchgear and control gear Degrees of protection provided by enclosures ( IP code) IS 1248 4411 5001 5469 13703 1652 6619 7204 14901 60947 60529

In case of any contradiction between various referred standards/specification/data sheets and statutory regulations, it shall be brought to the notice of Client for resolution. Generally the following order of priority shall govern, Statutory regulations BASF Guidlines Data Sheets This specification Codes and standards

1.3

Service Conditions 1.3.1 Equipment shall have a design life of 25 years, except batteries, which shall have the life details in the data sheet for the battery specified. 1.3.2 The Equipment shall be designed for a design ambient temperature of +45oC and an altitude not exceeding 1000 meters above mean sea level. Relative humidity of 92% shall be considered for design. 1.3.3 1.3.4 The equipments shall be suitable for operating satisfactorily indoors. Batteries shall be rated for continuous operation at 40C.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 6 of 13

BATTERY AND BATTERY CHARGER 1.4 Reliability /Availability 1.4.1 All Necessary care shall be taken in selection, design manufacturing and testing of equipment for ensuring high reliability. 1.4.2 The equipment reliability shall be given in terms of MTBF and MTTR values. Theses shall be calculated as per method specified in IEEE / IEC standard. 2.0 TECHNICAL REQUIREMENTS 2.1 General 2.1.1 The DC supply system shall have the continuous rating suitable to the operating load. The basis of rating selection shall have to be furnished with bid. 2.1.2 Battery shall be suitable to supply load for standby time as asked in data sheet and maintain the output supply voltage to the loads for entire duration. 2.1.3 2.2 Cable entry shall be from bottom.

Design Criteria 2.2.1 The DC SUPPLY SYSTEM shall be the sellers standard design for the specified system operating performance and environmental conditions. 2.2.2

Supplier shall have to provide the battery & battery charger selection calculation for following condition:
Nominal System Voltage Minimum System Voltage Max Voltage during float operation End of Cell Voltage No. of cells

110 Volt 99 Volt 121 Volt 1.85 Volt


55 Nos.

Ageing Factor Design Margin

1.25 1.10

2.2.3

The DC SUPPLY SYSTEM shall be configured so that under normal operation conditions the rectifier shall both provide power to the load, and maintain the battery under float charge conditions.

2.2.4 2.2.5

On failure of the mains supply the battery shall provide power to the load. The battery shall also have sufficient capacity to operate short circuit protection rated at 25% of the rectifiers rated output within 3ms of a fault.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 7 of 13

BATTERY AND BATTERY CHARGER 2.2.6 The DC SUPPLY SYSTEM shall be designed to achieve an overall minimum efficiency at rated load of 85% for single phase units and 90 % for three phase units. 2.3 Rectifier 2.3.1 The rectifier shall be of solid state construction, filtered output, and constant voltage type. 2.3.2 The equipment shall be designed to limit the total harmonic voltage distortion imposed on the incoming supply to 5%, based on the minimum system short circuit capacity specified. 2.3.3 Rectifiers for sealed lead acid batteries shall have a temperature compensated float charge rate only. 2.3.4 The rectifier shall be equipped with a timed walk-in circuit that causes the rectifier to assume the load gradually after input voltage is applied. 2.3.5 Dual rectifier systems shall be capable of parallel operation; each rectifier shall be rated for the total load. 2.3.6 The rectifier shall be rated to provide all system loads and to simultaneously recharge a completely discharged battery to 95% of full charge within 15 hours. 2.3.7 The rectifier shall provide a dc output voltage with the battery disconnected, controlled to within +/- 1% of the set value. The set value shall be adjustable. The battery manufacturers recommendations for rectifier voltage and charging current shall be adhere to under all operating conditions. 2.3.8 The rectifier shall be capable of limited the output current to a maximum of 125% of its rating, under any condition of load demand. 2.3.9 Dual rectifier systems shall be capable of parallel operation, but each rectifier and battery shall be rated for the total load. A no- break supply shall be maintained to the load during all switching operations 2.4 Internal DC Distribution Board 2.4.1 A DC Distribution board shall have to be provided inside the battery charger cubicle assembly with access available only when the front door is open. 2.4.2 2.4.3 Blocking diodes and isolators shall be provided in each incoming circuit. Each outgoing circuit shall be provided with an earth fault indication device.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 8 of 13

BATTERY AND BATTERY CHARGER 2.5 Control and Instrumentation 2.5.1 Each system shall be equipped with the following control devices: Rectifier input isolation switch Battery isolation switch Rectifier on/off switch DC voltage and current limit adjustment

Switches shall be lockable in the off position and accessible with the doors closed. Adjustments shall be provided with restricted access. 2.5.2 Each assembly shall have front panel graphic diagram (mimic) incorporating symbols for all the controls, switches, meters, alarms, and indicators for operation of the DC SUPPLY SYSTEM. 2.5.3 To prevent total discharge or damage to the battery, the battery charger must transfer to standby operation when the voltage reaches a set minimum voltage level. This parameter shall be user programmable. In case, AC input source does not return within 10 minutes after Low Battery indication, the charger shall electronically disconnect DC power from the battery to avoid deep discharge. 2.5.4 A battery monitoring system capable of monitoring and defining battery capacity shall be incorporated in the system. It must be possible to program this system to perform Automatic Battery Test to check the condition of the battery 2.5.5 Indicating meters shall be panel mounted on the front of the equipment and have 2% accuracy. The following meters are required: DC Voltmeter Battery DC ammeter (centre zero) Rectifier DC ammeter. Load DC ammeter. Earth indicating DC voltmeter with 3-position Negative- to earth , off , Positive to earth switch 2.5.6 The following indications shall be supplied:
G3IR-1050-65-SP-9037_R0

Rectifier supply available Rectifier on Cooling fan operation Rectifier over temperature. Low battery indication
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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 9 of 13

BATTERY AND BATTERY CHARGER 2.5.7 A common alarm output comprising potential free change over contacts shall be provided for : 2.6 Battery 2.6.1 2.6.2 The battery bank shall consist of sealed lead acid recombination type cells. The cell container and covers shall be moulded from a material that is resistant to heat, shock and chemical attack. The cell cover shall be permanently sealed to the container to form a non-leaking seal. Covers shall, where appropriates to battery type be equipped with explosion resistant, flame arresting vent caps. 2.6.3 2.6.4 Cell posts shall be sealed against creepage of electrolyte. The battery shall be rated to maintain the output voltage within tolerance, with the rectifier out of service, for the specified period under full load conditions at the end of battery life. Life time calculations shall be based on specified service conditions and 25 % additional capacity allowance for ageing. 2.7 Battery Support 2.7.1 2.7.2 Batteries shall be located on racks Battery racks shall be constructed of steel, coated with a material that resists the corrosive effects of spilled electrolyte, and designed to meet the specified UBC (Uniform Building Code) Seismic rating. Trays of corrosion resistance plastic shall be provided under each rack, to contain electrolyte spillage or leakage. 2.7.3 Battery racks shall include removable panels constructed of 6 mm thick plexiglass that shall enclose the battery rack. Panels shall be fastened with stainless steel screws, and the panels shall be installed on the front, top, and sides of the battery rack. The rear of the battery rack shall be open. 2.8 Battery Disconnector 2.8.1 The battery input power connected to the system shall be through a 2-pole overcurrent protection device for battery disconnection and Fault protection. Incoming supply failed Rectifier failed Earth fault Battery low volts Cooling fan failure Rectifier over temperature

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 10 of 13

BATTERY AND BATTERY CHARGER 2.8.2 The disconnector shall be mounted in the rectifier enclosure and shall be manually operable from the front of the enclosure with the doors enclosed. 2.9 Battery Accessories 2.9.1 Batteries shall be complete with shrouded terminals, insulated inter-cell connectors and insulated inter-tier jumpers. Inter-cell connectors shall be lead plated copper for lead acid batteries. Bolts, washers, and nuts shall be stainless steel provide high torque, low resistance terminations 2.9.2 Each battery bank shall have the following maintenance accessories: 2.10 Cell number and warning labels One cell lifting devices One container of non-oxide grease One set of maintenance equipment for breathing type cells

Equipment enclosure 2.10.1 Panel type enclosure shall be provided for the rectifiers and output distribution assemblies. 2.10.2 Enclosures shall be fabricated from sheet steel and have degree of protection IP3X with all enclosure access doors/panels closed. A minimum degree of protection of IP20 shall be maintained to live components when the enclosure front panel access doors are opened for inspection of the equipment. 2.10.3 Enclosure ventilation by natural air circulation is preferred; however equipment with filtered forced ventilation may be supplied provided that dual redundant cooling fans are installed. 2.10.4 Provisions shall be made for owner's cable entering from bottom of enclosure. A removable undrilled gland plate shall be provided at each conduit/cable entry position. 2.10.5 Interconnecting cable shall be provided between the rectifier, DC distribution board and battery bank. 2.10.6 Terminal blocks shall be provided for all incoming cable and labeled with the same number as the internal wire number that is connected to it. 2.10.7 Copper, compression type lugs shall be provided for all incoming and outgoing cables. 2.10.8 Earthing terminals shall be provided both internally and externally on panels.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 11 of 13

BATTERY AND BATTERY CHARGER

2.11

Painting and Finishing 2.11.1 Top coat paint shade / color shall be as RAL 7036. 2.11.2 The switchgear shall be cleaned, primed, and painted in accordance with Vendor's standard practice for the environmental conditions specified. 2.11.3 Supplier shall supply paint, matching each colour used, for field touch-up after installation of the equipment.

2.12

Equipment Identification 2.12.1 All warning, identification and instruction labels shall be inscribed in both the English and local languages. 2.12.2 Labels shall be engraved, laminated plastic secured by screws. Duty labels shall have black characters on a white background and warning labels shall have black characters on a yellow background. 2.12.3 Labels shall be installed for the following: Equipment title top/ centre of panel suite Circuit nameplate front of each panel Rating plate- inside each unit , indicating normal and maximum rating Instrument nameplates Component nameplates Battery title (supplied loose when rack mounted)

2.12.4 Components shall be marked with their ratings and any other essential data. 2.13 Noise 2.13.1 The audible noise level of the system equipment shall not exceed a sound pressure level of 70 dBA, measured at 1 meter from the nearest surface of the DC supply system requirement under all load conditions. 2.13.2 No single frequency shall exceed the mean by more than 10 dB for 20 Hz 20 kHz. 3.0 INSPECTION AND TESTS a) Visual checks and tests to prove operation of the equipment and protective devices shall be carried out on Battery & Battery charger system by the Supplier. Such tests may be witnessed at the discretion of the owner.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 12 of 13

BATTERY AND BATTERY CHARGER b) The following test shall be performed on each system: Insulation Resistance Performed on all equipment, to manufacturers recommended voltages, at beginning and end of test programme. Soak Test Performed at rated voltage and rated current continuously for at least 48 hours without failure. Rectifier Load Test at constant Output Voltage The following measurements shall be recorded at zero, 50 % and 100 % of full load direct current and shall be repeated at Plus 10 % and minus 10 % of the nominal supply voltage: o o o o Input phase voltage, current, and frequency Input Power DC output Voltage and current Output Voltage ripple

Rectifier Load test at constant Output current limit The DC output voltage and current shall be recorded when the rectifier is operating under DC output and current limiting conditions, at output voltages between zero and the set value corresponding to constant voltage operation.

Measurement of ripple by oscilloscope. Operation Tests All Devices shall be checked for correct operation

c)

Type Test of Battery Contractor shall submit type test reports of following tests as per IEC 60896-21 & IEC 6089622, 2004. S. No. 1 2 3 4 Description of test Gas emission High current tolerance Short circuit current and d.c. internal resistance Protection against internal ignition from external spark sources

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9037 Date 19-Jul-12 Page 13 of 13

BATTERY AND BATTERY CHARGER 5 6 7 8 9 10 11 12 Protection against ground short propensity Content & durability of required markings Material identification Valve operation Flammability rating of materials Intercell connector performance Recharge behavior Service life at an operating temperature of 400 C for brief duration exposure time 13 14 15 16 Abusive over-discharge Thermal runaway sensitivity Low temperature sensitivity Stability against mechanical abuse of units during installation

d)

Battery Discharge Tests This will be performed at site under sellers / manufacturers guarantees. With the rectifier connected to the load, and operating at rated output current, the following measurements shall be recorded: Battery voltage after the specified discharge time. Battery discharge duration at the instant the rectifier is shutdown by the Low voltage monitor in the DC circuit.

e)

Copies of evidence of tests shall be submitted with any other data relevant to the tests carried out. Equipment shall not be despatched unless the test certificates have been approved by the buyer

4.0

SPARE PARTS Bidder shall submit list of spares recommended by him for satisfactory operation of the DC Supply System for first two (2) years and rate for each spare shall also be quoted. The owner will decide the actual quantity of spare parts to be ordered on the basis of the prices of the spare parts, quoted by the bidder.

5.0

DRAWINGS AND DOCUMENTS The Vendor shall furnish drawings in accordance with SDDC form, enclosed with the Bid.

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