VES - 6405

STATIC RECTIFIERS AND BATTERY BANKS

TABLE OF CONTENTS
PAGE
1.0

SCOPE OF WORK

2.0

CODES AND STANDARDS

3.0

SITE CONDITIONS

3.1
3.2

3
3

Environment
Rating

4.0

SYSTEM OPERATION

5.0

GENERAL

6.0

SOLID STATE RECTIFIER

7.0

BATTERY BANK

8.0

AUXILIARY EQUIPMENT

9.0

ENCLOSURE

10.0

WIRING

11.0

GROUNDING

12.0

LABELING

13.0

INSPECTION AND TESTING

14.0

WARRANTY

15.0

SPARES

16.0

DOCUMENTS REQUIRED

10

17.0

PREPARATION FOR SHIPMENT

10

18.0

STATIC RECTIFIER AND BATTERY BANK DATA SHEET(S)

11

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VES-6405
Rev. 4, 11/02

1.0

2.0

SCOPE
1.1

This specification describes the minimum technical requirements for the design,
manufacture, testing and delivery for single phase and three phase solid state rectifier
and battery banks.

1.2

The purpose of these units is to supply direct current to vital and essential plant
systems and associated instrument and control devices, required for the safe
operation and control of plant shutdown under normal and emergency conditions.

1.3

Where the rectifiers and battery banks are utilized in conjunction with inverter
systems refer to specification VES-6400, Uninterruptable Power Supply (UPS)
systems for additional requirements.

CODES AND STANDARDS

The requirements of the latest editions of the following codes and standards shall form an
integral part of this specification except as noted herein.
ANSI
IEEE
NEMA
NFPA-70
VES-6000
VES-6050
VES-6200
VES-6400

3.0

American National Standards Institute

Institute of Electrical and Electronic Engineers
National Electrical Manufacturers Association
National Electric Code (NEC)
Installation of Plant Electrical Systems
Engineering and Design of Plant Electrical Systems
Electrical Cable
Uninterruptable Power Supply (UPS) System

SITE CONDITIONS
3.1

3.2

Environment
3.1.1

The battery bank unit shall be installed indoors in a separate battery room,
the battery room shall be provided with adequate ventilation to exhaust any
hydrogen gas to the outside air.

3.1.2

Ambient Temperature
Maximum
Minimum
Mean Relative Humidity

:
:
:

105oF (40oC)
65oF (18oC)
80% - 100%

Rating
3.2.1

The equipment shall be continuously rated for operation in an ambient

temperature of 40oC and ambient air of a relative humidity of 100%.

3.2.2

The altitude will not exceed 1000 meters above mean sea level.

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VES-6405
Rev. 4, 11/02

4.0

SYSTEM OPERATION
4.1

5.0

The D.C. power supply system shall operate as follows:

4.1.1

Under normal conditions, both rectifier, and battery bank will be connected
to the load (floating).

4.1.2

During prime power failure the batteries will automatically supply the load.
No switching shall be employed in this transfer.

4.1.3

On assumption of power the rectifier shall automatically be reset to equalize

charge as determined by the latest setting of the time switch to the
predetermined setting (usually 14 hours). On completion of the equalized
charge time setting the rectifier will automatically return to the float mode of
operation.

GENERAL
5.1

The load requirements and rectifier input voltage are specified on the data sheet(s).

5.2

The rectifier and battery bank unit shall be capable of supplying the maximum load,
continuously with prime power available. The rectifier capacity shall meet the output
of the unit as indicated on the data sheets and the following battery charge
requirements.
5.2.1

The rectifier shall be capable of charging the battery bank on equalize

charge from the discharged condition to 95 percent fully charged condition
in 14 hours with the external load connected.

5.3

The batteries shall be sized so that on prime power failure the batteries will supply the
maximum load current output for the full time specified on the data sheets, without
the voltage falling below the specified minimum volt/cell value.

5.4

Each unit shall consist of a rectifier, battery bank and auxiliary equipment. The
rectifier shall be housed in a free standing sheet metal cabinet suitable for the
specified area classification. The batteries shall be mounted on stepped type floor
mounted battery rack so that the electrolyte level of all cells is clearly visible.

5.5

The D.C. power supply shall be underground, i.e., floating output.

5.6

All components shall be of a proven quality, of current manufacture and shall be rated
to withstand normal variations in prime power voltage, current and frequency.

5.7

The rectifier, battery bank unit shall be designed to maximize personnel safety during
all operating, inspection and maintenance situations.

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VES-6405
Rev. 4, 11/02

6.0

SOLID STATE RECTIFIER

6.1

The rectifier shall be constant-voltage, current-limiting type designed to operate with

the battery bank in parallel, so as to provide an uninterrupted power supply to the
load, in the event of loss of A.C. power to the rectifier.

6.2

No inversion or switching shall be employed. Loss of rectifier input supply shall not
disrupt battery supply to the load.

6.3

The rectifier shall be supplied with float and equalize charging facilities as follows:
6.3.1

Float Charging
Under normal operating conditions the rectifier shall operate on floating
charge, supplying charging current to the batteries to compensate for the
self discharged of the batter bank. The float level voltage shall be factory
adjusted to offer the best compromise between keeping the battery bank
fully charged and minimum maintenance.

6.3.2

Equalize Charging
The rectifier shall be equipped with equalize charge facilities to quickly
recharge the discharged battery bank. The equalize charge mode shall be
initiated automatically (once primary power returns) with a manual provision
that allows setting a switch or timer. The equalize charge circuit shall be
supplied with an automatic facility to revert the rectifier back to float charging
mode, when the batter bank becomes fully charged.

6.4

The rectifier shall be protected against overloading by the installation of a current

limiting device which shall limit the rectifier output to 140 percent of its output current
rating.

6.5

The rectifier shall incorporate devices to protect components against harmful

transients from the power supply to the rectifier, high inrush and overload currents,
overcharging of batteries and short circuit conditions.

6.6

Rectifier Output Variations

6.6.1

Based on a variation in the A.C. power supply to the rectifier of plus 10

percent to minus 10 percent rated voltage and plus 5 percent to minus 5
percent hertz respectively the direct current output shall not exceed the
following:
a.
b.
c.

6.6.2

Voltage Regulation 1% pre-set value

Ripple Factor
5% RMS
Current Regulation 1% pre-set value

The maximum allowable voltage fluctuation as determined by the load is

limited to plus 10 percent and minus 10 percent of the nominal rated value.

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VES-6405
Rev. 4, 11/02

7.0

8.0

BATTERY BANK
7.1

The battery size shall be in accordance with the data given on the data sheet(s).
Unless otherwise stated on the data sheet(s) the batteries shall be Nickel-Cadmium
type.

7.2

Nickel-Cadmium batteries shall have a life expectancy of not less than 15 years. The
battery plates shall be contained in high volume plastic electrolyte containers with
visual electrolyte level. The plastic containers shall be of non-flame-propagating,
shock resistant material.

7.3

The batteries shall be supplied complete with mounting racks, proper connectors,
filling funnels, hydrometer, glass measuring jug, instruction book, chart of cell voltage
discharge characteristics and 0.5 pound of oxide resistant grease.

7.4

The batteries shall be supplied discharged and without electrolyte. Electrolyte for the
batteries shall be supplied in separate, adequately protected containers.

7.5

Batteries shall be complete with all necessary links and cable lugs.

7.6

Protective covers for terminals shall be provided.

7.7

Battery racks shall be of suitably sized 90o angle iron construction, stepped type with
insulated runners supplied in knocked down assembly. The battery rack shall be
blasted to near white SA 22 and painted with two coats of alkali resistant finish.

AUXILIARY EQUIPMENT
8.1

All components for controlling, measuring and protection of the rectifier shall be built
into the cabinet in accordance with manufacturer's standard, but logically grouped for
the rectifier operation.
The following accessories shall be provided as a minimum:
8.1.1

Switches
a.
b.
c.

8.1.2

Rectifier A.C. mains ON-OFF switch

Rectifier 0-24 hours equalizing timer
Ground detection switch

Measuring Instruments
a.
b.

Voltmeter - Rectifier D.C. output

Ammeter - D.C. load

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VES-6405
Rev. 4, 11/02

8.1.3

Indicating Lights
a.
b.

8.1.4

Mains A.C. supply "ON"

Ground detection positive and negative Lights

Alarms
a.
b.
c.
d.
e.

Mains failure
Charge failure
Ground fault
Overvoltage
Undervoltage

A common unit malfunction alarm relay shall be provided for external

monitoring of the unit.
8.1.5

Fuses
Fuses shall be of the high-interrupt capacity cartridge type which fit in to the
fuse holder by knife blade contacts.

9.0

ENCLOSURE
9.1

The rectifier unit enclosure shall be fabricated from steel sheet to form a free
standing cabinet sufficiently rigid to prevent distortion during lifting, jacking and
transportation.

9.2

The cabinet shall be suitably partitioned between the individual items to allow for
maintenance or repairs to be carried out in a safe way.

9.3

Enclosure design shall be in compliance with the area classification specified on the
data sheet.

9.4

The cabinet shall be front access only with natural ventilation.

9.5

Lifting lugs, or other approved method, shall be provided to facilitate handling.

9.6

Painting and finish shall be to the manufacturer's standard for the service conditions
specified. Details thereof shall be provided in the Tender for Company approval.

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VES-6405
Rev. 4, 11/02

10.0

11.0

12.0

WIRING
10.1

Wire shall be run in harnessed bundles or in ventilated plastic tray with covers
(panduit type). Refer to VES-6000, Installation of Plant Electrical Systems.

10.2

Power wiring shall be generously sized and derated for maximum ambient
temperatures within the cabinets.

10.3

Conductors shall be stranded copper. Insulation shall be rated for 600 V minimum.
Color coding shall be provided in compliance with VES-6050, Engineering and Design
of Plant Electrical Systems.

10.4

Terminals shall be Klippon or approved equal and shall be numbered. No more than
one wire shall be terminated on one terminal.

10.5

All wires shall have plastic ferrules at both ends, numbered in accordance with the
relevant wiring diagrams.

GROUNDING
11.1

The cabinet shall be provided with a copper ground lug for connection to the plant
grounding system.

11.2

All non-current carrying metal parts shall be bonded to provide a continuous ground to
the ground lug. Door hinges are not acceptable ground paths.

11.3

The battery and charger output shall not be grounded unless otherwise specified on
the data sheet(s).

LABELING
12.1

Every item of equipment shall be identified with an equipment tag bearing the tag
number appearing on the relevant drawings and the item service description.

12.2

Name plates on the front of cabinets shall be plastic laminate, white background,
black letters. They shall be attached to the cabinets with stainless steel screws.
Adhesive is not acceptable.

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VES-6405
Rev. 4, 11/02

13.0

INSPECTION AND TESTING

13.1

Purchaser reserves the right to witness all tests and shall be notified at least four
weeks in advance.

13.2

The following tests shall be conducted:

a. Visual inspection to ensure that workmanship, good practice and finishes were
maintained during manufacture and assembly.
b. Quantitative check to ensure that all items in accordance with the purchase order
and packing list are present.
c. Continuity test of all electrical circuits.
d. Insulation resistance tests.
e. Twenty-four (24) hour performance test to ensure that all equipment operates
correctly.
The results of all tests carried out shall be recorded and shall be submitted to
Company on completion of testing and included in Vendor documentation manual.

14.0

15.0

WARRANTY
14.1

The warranty of the entire assembly shall be the responsibility of Vendor. The
warranty period shall be a minimum of 24 month, after shipment or 12 month after
commissioning.

14.2

Vendor shall replace or repair any portion of the equipment which is defective at his
own cost during the warranty period at a time suitable to Purchaser.

SPARES
Vendor shall include priced recommended spare parts for start-up and for one (1) year of
operation with proposal. Recommended spares should take into account related factors of
equipment reliability, remote location and availability of equipment service facilities. Vendor's
complete spare parts list shall be issued to Purchaser within four (4) weeks after receipt of
order.

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VES-6405
Rev. 4, 11/02

16.0

DOCUMENTS REQUIRED
Vendor shall furnish the following documentation prior to final invoicing. Ten (10) sets of
engineering documents shall specifically include.
a)
b)
c)
d)
e)
f)
g)

17.0

Operating Manuals
Maintenance Manuals
Manufacturer's Spare Parts List
Control Schematics and wiring diagrams
Printed Circuit Board Layouts
Dimensioned Outline Drawings
Rectifier Unit Test Report

PREPARATION FOR SHIPMENT

17.1

The batteries shall be shipped dry.

17.2

Instrument indicators shall be locked where possible.

17.3

Plug in components and component parts which may not be securely supported by
their sockets during shipment shall be removed, packaged separately and securely
stored within the cabinet. Adequate identification and instructions for remounting
shall be contained in each package.

17.4

All equipment shall be packed and crated so that it is fully protected from damage and
the effects of weather during transport and outdoor storage on site. Desiccant bags
shall be included with the rectifier which shall be sealed in plastic.

17.5

The outside of the crate shall be clearly marked with job (AFE) number, order
number, contents, destination, and total weight. Destination data shall be as detailed
on the Purchase Order.

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VES-6405
Rev. 4, 11/02

18.0

DATA SHEET
CONDITIONS
1

GENERAL REQUIREMENTS: GENERAL SPECIFICATION STATIC RECTIFIERS & BATTERY

RECTIFIER

BATTERY

INPUT VOLTAGE

BATTERY CAPACITY

................. V .......... PHASE EARTH

........................ AMP HOURS

50 HZ ........................ WIRE

TO DELIVER A MAXIMUM LOAD OF ..........................

RATED OUTPUT

........................ AMPS FOR .....................

............................. V.D.C NOT EARTHED

TO AN VOLTAGE OF ............................... V/CELL

................. AMPS ..................... KW

10

BATTERY TYPE

11

Ni-Cd/Pb ..............................................

12

A.C. CABLING

13

CABLE ENTRY - TOP/BOTTOM

CABLE ENTRY - TOP/BOTTOM

14

CABLE TYPE:

CABLE TYPE:

15

CABLE SIZE:

16

D.C. CABLING

CABLE SIZE:
INFORMATION TO BE SUBMITTED WITH TENDER

17

RATED OUTPUT:
VOLTS

KW

A AT

18

MAXIMUM INPUT:

KW

A AT

19

RECTIFIER EFFICIENCY:

20

TOTAL HEAT LOSS:

21

MAXIMUM A.C. MAIN FUSE RATING:

22

BATTERY:

23

NUMBER OF CELLS:

24

TOTAL MASS:
OVERALL DIMENSIONS

26

RECTIFIER/BATTERY UNIT

27

RECTIFIER

28

BATTERY BANKS

HALF

FULL LOAD
A

MAKE

25

VOLTS

FULL LOAD

TYPE Ni-Cd/Pb
KG

LENGTH

29

WIDTH

DEPTH

SPECIAL REQUIREMENTS

30

VES-6405
Rev. 3, 4/93

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