Section C Technical Specifications of Stores PDF

KAKRAPAR ATOMIC POWER STATION
UNITS 1 & 2 (220 MWe)
PROCUREMENT SPECIFICATION NO. KAPS/52324/PB SEPC./001
SPECIFICATION FOR POWER BATTERIES
Prepared By: Checked By: Reviewed By: Approved By:
Kapil Mishra Ulhas Pethkar P. Barik S K Deshmukh V K Sharma

SO/E , EMU SO/F,KAPS SME(E), MS CS-KAPS
KAPS
REVISION NO. : R1
DATE : Oct-2016
Revision Control Sheet
Document type: Technical Specification
Document No: KAPS/52324/PB SEPC./001
Title: Specification for Power Batteries of KAPS
(Kakarapar Atomic Power Station-1 & 2)
Rev. No. Date Description of Prepared by Checked By Reviewed by Approved by

Revision
First issue Kapil Mishra P Barik S K Deshmukh V K Sharma
Ro SO/D , EMU SME(E) MS CS-KAPS
Oct-2015
U Petkar
SO/F , EMU
R1 Revision in Kapil Mishra P Barik S K Deshmukh V K Sharma
Oct-2016 specification as per SO/D , EMU SME(E) MS CS-KAPS
designer review
U Petkar
SO/F , EMU
NUCLEAR POWER CORPORATION OF INDIA LIMITED
( A Government of India Enterprise )
KAKARAPAR ATOMIC POWER STATION

UNITS 1 &2
SPECIFICATION FOR
POWER BATTERIES
SPECIFICATION No.: KAPS/52324/PB SEPC./001 Oct-2016

Revision 1
Technical Specification for Power Batteries for KAPS-1 &2.
SECTION : CONTENTS
Tender document CONTENTS SHEET 1 OF 1
Revision-0
SECTION TITLE NO.OF SHEETS
CC-1 Scope of Supply/Work/Services 3
CC-2 Applicable Codes, Standards and Specifications 2
CC-3 Specification of Main Equipment and Accessories 5
CC-4 Equipment Construction & Design Details 12
CC-5 Inspection & Testing 8
CC-6 Quality Surveillance 3
CC-7 Tender Evaluation 1
CC-8 Tests at Site 3
CC-9 Special Tools & Tackles for Erection & Maintenance 1
CC-10 List of Drawings enclosed 1
CC-11 Annexures 1
D. FORMAT FOR SUBMISSION OF PART I (TECHNICAL)

OF THE TENDER
D1 Technical Data 8
D2.1 Schedule of proposed equipment manufacturer’s

General Particulars 1
D2.2 Schedule of Tenderer’s Experience 1
D2.3 Drawings to be submitted along with the Tender 1
D2.4 Performance Data, including performance curves, etc. to be 1

Submitted along with the tender
D2.5 Schedule of submission of drawings, data, instruction manuals, 2

Test reports etc.
D2.6 Schedule of Performance Guarantee 1
D2.7 Schedule of Deviations from Technical Specifications 1
D2.8 Schedule of Manufacturing, delivery and other related activities 1
D2.9 Schedule of Personnel for Erection, Testing & Commissioning 1
SPECIFICATION No.: KAPS/52324/PB SEPC./001 Oct-2015

Nuclear Power Corporation Of India Limited
Kakrapar Atomic Power Station Unit 1&2 Section : CC1
Technical Specification For Power Batteries for KAPS-1&2 Page 1 of 3
SCOPE OF SUPPLY/WORK/SERVICES Rev-1
1.0 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 220 MWe
PHWR Kakrapar Atomic Power Station Units-1 & 2.
Quantity
Sr. Battery Locati
Ampere Hour Capacity (min)
No. Designation on KAPS-1 KAPS-2
354 V DC POWER BATTERIES (177 no cells/bank) along with stands
1 52324-BY-1 Tubular battery (TBS- Lead acid cells
with tubular positive plates and pasted TB-1 & 2
negative plates housed in SAN (106 M EL)
1 1
transparent containers):
2435 AH (Min.)*
2 52324-BY-2 Tubular battery (TBS- Lead acid cells TB-1 & 2

with tubular positive plates and pasted (106 M EL)
negative plates housed in SAN
transparent containers): 1 1
2435 AH (Min.)*
Tag No. of equipments supplied for KAPS-1 shall be pre-fixed by 1 and those for KAPS-2
shall be prefixed by 2.
* : 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
2.0 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/52324/PB SEPC./001 July-2013

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-10.
9.0 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.
10.0 SUPPLIER shall provide the double earthing to battery stand, supply of earthing cable and
proper fixing shall be in the scope of SUPPLIER.
11.0 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.
12.0 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.
13.0 Spare parts and maintenance tools, as described in Sections CC-2 of this Specification, shall
be supplied by the SUPPLIER.

14.0 SUPPLIER shall supply one trolley for handling, lifting and shifting of battery cells.
15.0 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.
16.0 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.
17.0 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.
18. “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.”

Technical Specification for Power Batteries for KAPS-1 & 2.
Kakrapar Atomic Power Station Unit 1&2 Section: CC-2

Tender Technical Specification For Power Batteries for KAPS-
Document 1&2 Sheet 1 of 2
APPLICABLE CODES, STANDARDS AND
SPECIFICATIONS
R1
1.0 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.
2.0 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
1) IS:266 Sulphuric Acid.
2) IS:1069 Quality tolerances for water for storage

batteries.
3) IS:1146 Rubber and plastic containers for lead-acid

storage batteries.
4) IS:1651:2013 Stationary cells and batteries, lead-acid type with

Tubular positive plates.
SPECIFICATION NO: KAPS/52324/PB SEPC./001 Oct-2015


Tender Technical Specification For Power Batteries for KAPS-
Document 1&2 Sheet 2 of 2
APPLICABLE CODES, STANDARDS AND
SPECIFICATIONS
R1
CODE TITLE
5) IS:1885 Electrotechnical vocabulary: (Part VIII)

Secondary cells and batteries.
6) IS:3116 Sealing compound for lead-acid batteries.
7) IS:4905 Methods for random sampling.
8) IS:6071 Synthetic separators for lead-acid batteries.

9) IS:8320 General requirements and methods of test for
lead-acid storage batteries.
10) IEEE:344 Recommended practice for seismic qualification
of Class-1E equipment for Nuclear power
generation station.
11) IEEE:450 Recommended practice for maintenance, testing

and replacement of large lead storage batteries
for generating stations and sub- stations.
12) IEEE:484 Recommended practice for installation design

and installation of large lead storage batteries for
generating stations and sub- stations.
13) IEEE:485 Recommended practice for sizing large lead

storage batteries for generating stations and sub-
stations.
14) IEEE:535 Standard for qualification of Class-1E lead

storage batteries for Nuclear power generating
stations.

Section: CC-3
Kakrapar Atomic Power Station Unit 1&2
Tender Document Technical Specification For Power Batteries for KAPS-1&2
SPECIFICATION OF MAIN Sheet 1 of 5
EQUIPMENT AND ACCESSORIES R1
1.0 This section covers the specific requirements for lead acid batteries:
DATA SHEETS
Technical Requirements for Lead Acid Batteries:
SR. DESCRIPTION POWER BATTERIES

NO.
1.1 Application Stationary battery for DC back-up to Power
UPS
1.2 Type of cells Lead acid cells with Tubular type positive
plates(TBS Type).
1.3 DC System Voltage
1.3.1 Nominal Voltage 354 V DC (177 x 2.0 V)
1.3.2 Maximum Voltage during:
(a) Boost charging Up to 490V DC
(b) Equalizing Charging Up to 425 V DC
(c) Float charging Up to 400 V DC

1.3.3 Minimum battery voltage 301 V DC
during duty cycle discharge
1.4 Cell voltages

1.4.1 Float voltage
2.18-2.28 VPC
1.4.2 Equalizing voltage considered 2.4 VPC
1.4.3 Max. Boost voltage considered

2.75 VPC
1.4.4 End of duty cycle discharge
voltage 1.7 VPC
1.5 Guaranteed load duty cycle Battery should give minimum back up time of
current on battery till its end of 30 minutes @1007 ampere DC and Power
cell voltage as per 1.4.4
considering no. of cells as per battery bank should also capable to give DC
back up of 08 hrs as per attached load duty cycle
clause 1.7 (Annexure-I).

Section: CC-3
1.6 Guaranteed Duty cycle As per manufacturer’s battery characteristics curve

discharge current applicable for offered battery and power battery should
requirement for new give minimum back up of 30 min @1007 A DC and
battery at 27 Deg C. power battery bank should also be capable to give DC
back up of 08 hrs. as per attached load duty cycle
(Inclusive of AM, DM (Annex-I)
and Temp correction
factors)
1.7 No. of Cells in series in 177 Cells
Battery Bank
1.8 Other factors to be The vendor shall review and state if any other factors
considered, if any. 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.
1.9 Ref. room ambient temp 8 to 45 Deg.C
for design of battery
1.10 Charger details
1.10.1 Type of charger Modified constant voltage with current limit.
1.10.2 Charger DC voltage

steady state stability + 1%
1.10.3 Ripple voltage Limited to 1% of voltage without battery connected.

1.10.4 Ripple current Shall be limited to 5% of C10 discharge current
1.10.5 Current limit during Max.12 % of C10 Capacity

charging
1.10.6 Maximum time the

battery can take for 8 Hrs.
recharging after a duty
cycle discharge so that it
is again ready for a
second duty cycle
discharge

Section: CC-3
1.11 Minimum accepted C10

AH capacity for the 2435AH
battery banks
2435 AH will be minimum accepted capacity , however
supplied battery should meet all other specification and
Tubular Positive Plate battery bank of 177 no. of cells shall give minimum back
up of 30 min @1007 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)
1.12 Factors to be considered Design margin: 10%, Aging Margin: 25%, Temperature
for battery sizing correction factor: 17%

Technical Specification for Power Battery for KAPS-1&2
Section: CC-3
Tender Document SPECIFICATION OF MAIN
EQUIPMENT AND ACCESSORIES Sheet 4 of 5
2.0 LIST OF ESSENTIAL SPARES & ACCESSORIES TO BE SUPPLIED
Following is the list of spares & accessories for testing and maintenance of lead-acid
battery bank
Sr. Item Description

Quantity
No. SPARES/ACCESSORIES/CONSUMABLES
1. Insulators for battery racks (if applicable) 50 Nos
2. Electrolyte of applicable specific gravity at 270C 5% of total quantity
3. Inter cell connectors with hardware 20 Nos
4. Inter row connectors with hardware 5 Nos
5. PVC/Polystyrene spill trays (if applicable) under Sufficient for min. 10 Nos of
cells cells
6. Vent plugs assembly 50 Nos
7. Spare nuts, bolts & washer 5% of total quantity
8. Inter cell insulated caps 10 Nos
9. Approved type digital multimeter RISHABH make,
5 Nos
model RISH Multi 18 S or equivalent
10. Approved type digital hydrometer (Density meter)
3 Nos
11. Approved type portable digital ‘hydrogen

concentration in air’ meter with range covering up 2 Nos
to minimum of 4 %
12. Acid resistance jugs of adequate capacity with
5 Nos
quantity markings.
13. Acid resistance funnels 5 Nos
14. Acid resistance Bucket 5 Nos
15. Rubber aprons and gloves 50 Nos
16. Digital PH meter and conductivity meters 5 no. each
17. Cell lifting straps (if required) 5 Nos
18. Insulated spanner set & Insulated torque wrench
covering all sizes of hardwares used in the battery 2 Nos
bank.
19. Syringe for handling electrolyte in cells 5 Nos
20. Filling plugs. 50 Nos
21. Under cell marine plywood for each stand (if 20 % of total qty subjected to
applicable) min. of one number.
SPECIFICATION NO: KAPS/52324/PB SEPC./001 July 2013

Technical Specification for Power Battery for KAPS-1&2
Section: CC-3
Tender Document SPECIFICATION OF MAIN
EQUIPMENT AND ACCESSORIES Sheet 5 of 5
Spare Battery racks of each type One number.
22. Approved type cell handling cum loading/

unloading trolley &/or set up for removal &
02 Nos
installation of cells in racks & handling the cells
from site storage area to battery room & vice versa
23. Petroleum jelly of approved make in 1 Kg pack for
100 Kgs
application on battery terminals/ connectors.
24. Spares cells (dry) - (combination of quantity for
15 Nos
end & intermediate cells subjected to approval)
25. Spare containers & lids 10 Nos
26. Cell lid Sealing compound 10 Kgs/ Ltrs
27. Filler hole thermometer suitable for measuring
battery electrolyte temperature. 08 nos.
28. Wall mounting type digital thermometer for battery

room temperature measurement. 08 nos.
29. Laminated wall mounting type. Instruction cards

indicating battery details, Battery TAG no. , safety, 08 nos.
operation & maintenance instructions.
NOTE:
1) One set of any item of spares shall include the quantity of all sizes and types of
that item.
2) 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.

Technical Specification for Power Batteries for KAPS 1 & 2

Technical Specification For Power Batteries for
Tender Document
KAPS-1&2 Sheet 1 of 12
EQUIPMENT CONSTRUCTION AND DESIGN
DETAILS
R1
1.0 SCOPE
1.1 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.
2.0 GENERAL
2.1 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.
2.2 There shall be no impurities, harmful to the performance or life of the cells.
2.3 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.
2.4 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
3.1 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-3.
3.1.1 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.
3.1.2 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.


Technical Specification For Power Batteries for
Tender Document
KAPS-1&2 Sheet 2 of 12
EQUIPMENT CONSTRUCTION AND DESIGN
DETAILS
R1
3.1.3 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 C10
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
3.1.4 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 C10 discharge.

Tender Document Section: CC-4
EQUIPMENT CONSTRUCTION AND Sheet 3 of 12
DESIGN DETAILS
Volume –II
REVISION 0
4.0 CAPACITY
4.1 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 10% 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.
4.2 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-10 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 27°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-10 of this specification. The

DESIGN DETAILS
Volume –II
REVISION 0
battery layout should provide sufficient clearances from the walls and columns ofthe
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:
484.
6.0 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 C10 capacity discharges and duty cycle discharges under
the maximum ambient conditions specified.
7.0 VENTILATION AND ROOM LAYOUT
7.1 The following ventilation arrangement is being provided by the PURCHASER.
7.1.1 The battery rooms will be provided with exhaust fans to limit the hydrogen
concentration to less than 1% by volume. Battery room temperature can be
conservatively considered same as outside ambient.
7.1.2 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.
7.2 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.

Technical Specification for Power Batteries for KAPS-1&2.
DESIGN DETAILS
REVISION 0
8.0 INTERCHANGEABILITY
8.1 All identical components and corresponding parts shall be fully interchangeable without
having to carry out any modifications.
8.2 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
9.1 Seismic Testing of Battery along with Stand.
9.1.1 354 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 (1) 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.
9.1.2 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.
9.2 Seismic Testing Co-ordination

DESIGN DETAILS
REVISION 0
9.2.1 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.
9.2.2 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'.
9.2.3 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 C10 capacity test before and after the seismic test.
9.2.4 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.

DESIGN DETAILS
REVISION 0
10.0 CONSTRUCTIONAL FEATURES
10.1 Plates
10.1.1 Tubular Positive Plates for Lead Acid Batteries
Tubular positive plates as per IS-1651:2013 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.
10.1.2 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
10.2 Containers
10.2.1 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.
10.2.2 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.
10.2.3 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.

DESIGN DETAILS
REVISION 0
10.3 Vent Plug
10.3.1 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.
10.4 Electrolyte Level Indicators
10.4.1 The maximum and minimum electrolyte levels shall be clearly marked on the outer
portion of container on all four sides of transparent containers
10.4.2 The marking shall be in red colour and shall be oxidation proof and free from the
action of electrolyte.
10.5 Separators
10.5.1 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-2.
10.5.2 Separator design and its assembly during cell manufacture shall ensure availability of
sufficient space for passage of material shed by positive and negative plates.
10.6 Connectors
10.6.1 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

DESIGN DETAILS
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:8130) 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 2.0 kV for 1 min.
10.7 Terminal Posts

10.7.1 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.
10.7.2 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.
10.8 Group Bars
10.8.1 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.
10.9 Electrolyte
10.9.1 The electrolyte for lead acid cells shall be battery grade sulphuric acid conforming to
latest editions of IS-266. 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.

DESIGN DETAILS
REVISION 0
10.10 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:1069.
10.11 Termination Facility for PURCHASER's Connections.
10.11.1 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.
11.0 Accessories for Testing & Maintenance
11.1 Each lead-acid battery bank shall be complete with all accessories and devices,
including, if required insulating pads for battery racks and cells.
11.2 Each cell, should have a permanent label indicating the cell number.
11.3 Suitable set of insulated spanners.
11.4 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
11.5 Cable clamps with hardware for supporting outgoing cables on battery.
12.0 BATTERY RACKS
12.1 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

DESIGN DETAILS
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.
12.2 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.
13.0 TRAINING REQUIREMENT:
Operational & maintenance training of the supplied battery type shall be provided to 20
(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-10 & 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.

DESIGN DETAILS
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.


Technical Specification For Power Batteries for KAPS-
Tender Document 1&2. Sheet 1 of 8
INSPECTION AND TESTING
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1.0 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.
2.0 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.


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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 (15) days
after completion of tests, but if the tests are not witnessed by the
PURCHASER's representative, the certificate shall be issued within fifteen
(15) 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.
10.0 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'.
11.0 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


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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.
12.0 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.
13.0 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.
14.0 SUB-ORDERS
14.1 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.


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14.2 In order to facilitate the inspection of bought-out materials and equipment,

the SUPPLIER shall submit for approval, three (3) copies of all sub-orders
placed by him as soon as they are issued. Copies of any drawings referred to
in the sub-order shall also be submitted, unless otherwise agreed by the
PURCHASER or his representative.
14.3 The sub-orders and drawings referred to above shall cover all components
which are subjected to electrical and mechanical pressure or stress when the
plant is in operation, and also auxiliaries and spares which are to be directly
dispatched to site from the SUB- CONTRACTOR's works.
14.4 All sub-orders shall clearly be marked with the main SUPPLIER's name and
the PURCHASER's reference. They shall include a statement advising the
SUB-CONTRACTOR that items being ordered will also be subject to
inspection and test by the PURCHASER or his representative.
14.5 It is important that all copies of sub-orders be clearly marked with the main
SUPPLIER's name and the name of the PURCHASER and 'Contract'
reference.
15.0 MATERIAL TESTS

15.1 In the event of the PURCHASER or his representative being supplied with
the particulars of tests which have been carried out for the SUPPLIER by the
suppliers of material, he may, at his own discretion, accept same as proper
evidence of compliance with the requirements of appropriate specifications for
the materials.
15.2 In case the correlating test certificates are not available the SUPPLIER, at no
extra cost to the PURCHASER will get all the tests done to establish
conformity of the material to its relevant code/ specification.
16.0 T ESTS AT MANUFACTURER’S WORKS
16.1 General
The tests at works shall include electrical, mechanical and hydraulic tests in
accordance with the appropriate clauses of Statutory Regulation, relevant
codes and standards and in addition any test called for by the
PURCHASER or his representative to ensure that the equipment being
supplied fulfills the requirements of the specification. The SUPPLIER shall
carry out all the shop tests and inspections specified in the following clauses
in addition to those normally carried out by him. For equipment not


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covered by any code or specifically mentioned in this specification, the tests

are to be agreed with the PURCHASER. If considered necessary by the
PURCHASER or his representative, multi-part assemblies shall be fully
erected and tested in the works prior to packing and despatch to the site.
16.2 The SUPPLIER shall carry out all tests as per latest edition of relevant
standards to show that the equipment has been satisfactorily designed and
manufactured. Inspection shall not be limited to the end product only.
Facilities shall be provided for inspection, during various stages of manufacture
as agreed at the time of placement of Purchase Order.
16.2.1 In addition to this, manufacturer shall perform any other test necessary to
furnish information requested in Section: D of this specification.
16.3 If some of the tests mentioned below, cannot be carried out at the Supplier's
works, the same shall be carried out at the site. In such a case, the supplier
shall indicate the procedure for the test. If the equipment does not pass the
test at site, it will be the Supplier's responsibility to replace the
faulty equipment at his cost. Any special equipment required for testing like,
meters, relays etc., if not available at Purchaser's site, shall be arranged by the
SUPPLIER.
16.4 All type tests and acceptance tests shall be carried out in presence of
PURCHASER's representative.
16.5 The type tests, acceptance tests and routine tests specified below shall be
conducted separately on each rating/capacity of battery covered by this tender
specification. The Bidder shall quote the unit prices for each type test in
Section E. The PURCHASER will decide on the type tests to be done at the
time of placement of order. The Bidder shall also indicate the date on which
the type tests were carried out. Subsequent to these type tests, if any design
changes have been carried out, the same should be listed out by Bidder in
Section D-2.4.
16.6 Type Tests
16.6.1 Type tests on Containers

16.6.1.1 The following type tests shall be carried on containers in accordance with IS :
1146:
a) Verification of constructional requirements.
b) Verification of marking and packing.
c) High voltage test.


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d) Drop ball test.

e) Plastic yield test.
f) Hydraulic thrust endurance test at elevated temperature.
g) Acid resistance test.
16.6.1.2 Containers used for type tests should not be included in the supply. Prices
quoted in Section E should include the cost of such containers used for type
tests.
16.6.2 Type Tests on Separators
Type tests on separators shall be carried out as per IS:6071. In case of other
plastic like PE any internationally acceptable standard recognising such
material shall be followed.
16.6.3 Type Test on Completed Cells
16.6.3.1 Following type tests specified in IS 1651 : 2013 shall be carried out on three
cells of battery:
a) Verification of constructional requirements.
b) Verification of marking.
c) Verification of dimensions.
d) Test for capacity.
e) Test for voltage during discharge.
f) Ampere-hour and watt hour efficiency tests.
g) Test for loss of capacity on storage.
h) Test for suitability of floating battery operation.

i) Short circuit current and internal resistance test.
j) Water loss test.
k) Endurance test.


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16.7 Acceptance Tests
16.7.1 Acceptance Tests for Containers

Acceptance tests as per IS: 1146 shall be carried out on the containers for lead
acid cells.
16.7.2 Acceptance Tests on Completed Cells
Acceptance tests as per IS 1651 :2013 shall be performed on samples drawn

from each lot of batteries comprising one battery bank.
16.8 Routine Tests
16.8.1 Routine Tests on Containers
Containers for all lead acid cells shall be tested in accordance with IS:1146.
16.9 Special test*
The following special test shall be carried out on three cells of

battery for which testing charge shall be clearly quoted by bidder.
16.9.1 Test for capacity shall be performed as per clause 1.6 of CC-3.
16.9.2 Seismic Qualification of power Batteries
At least 3 nos. of cells housed in a battery rack identical to the final
supply shall be subjected to seismic testing as specified in Section CC-4.
During the testing, the battery cells will be loaded as per IEEE-535, as
applicable. During the testing, the current and voltages shall be
monitored. The response spectra used for the test should be an envelope
of the response spectra in the same direction at the individual locations in
Turbine Building of the four sets of batteries covered by this
specification. The test and analysis shall be carried out in accordance
with IEEE: 344 and the approved test procedure.
* “Special test shall be conducted as per the discretion of the purchaser”
17.0 CALIBRATION OF INSTRUMENTS


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All the instruments/gauges used for testing shall be calibrated and traceable to
National Standards.
18.0 “The cells used for performance, acceptance, Type & special test etc. shall not
be part of regular battery bank.”
“All the equipments offered should have been successfully type tested
as per the relevant standards, amended up to date. In case the equipment
of the type and design offered has already been type tested, bidder shall
furnish type test reports before proceeding with manufacture. Type tests
must not have been conducted earlier than five years from the date of
opening of bids. In case the type tests were conducted earlier than five
years, such type tests shall be repeated by the successful bidder free of
cost before commencement of supply. The undertaking to this effect
shall be furnished along with the offer without which the offer shall be
liable for rejection. As a part of technical offer, bidder shall include a
tabulation detailing various type tests on each type of equipment along
with applicable type test certificate number, details of the equipment
subjected to type test, place of testing and final results.
The purchaser reserves the right to demand repetition of some or all the
type tests in the presence of his representative. For this purpose the
bidder shall quote unit rates for carrying out each type test.
If there are changes in the components or in the design/type already
type tested and the design/type offered against this specification, the
purchaser reserves the right to demand repetition of tests without any
extra cost before commencement of supply. The bidder shall bring out
in his offer all such changes made in components, materials, design etc.
as the case may be and likely effects of such changes on type
qualification.”

Section: CC-6
Tender Document Technical Specification For Power Batteries for KAPS-
1&2 Sheet 1 of 3
QUALITY SURVEILLANCE R1
1.0 On award of the contract, the CONTRACTOR shall prepare Quality Control
Plan identifying the various stages of manufacture, quality checks performed
at each stage and the Customer hold points. The document shall also furnish
details of method of checking, inspection and acceptance standards / values
and get the approval of PURCHASER or his representative before
proceeding with manufacturing. However, PURCHASER or his
representative shall have the right to review the inspection reports, quality
checks and results of Contractor’s in-house inspection department which are
not Customer hold points and the CONTRACTOR shall comply with the
remarks made by PURCHASER or his representative on such reviews with
regards to further testing, rectification or rejection etc. A typical quality
control plan is enclosed and the requirements of this quality control plan shall
be included in the quality control plan to be submitted after placement of
order.
2.0 The CONTRACTOR shall submit a detailed quality assurance manual to

ensure that the equipment and service under the scope of this contract,
whether manufactured or performed within his works or at his SUB-
Contractor’s works or at Purchaser’s site or at any other place of work are in
accordance with the specified requirements. The quality assurance manual
shall cover the aspects as indicated in various standard specifications of
Section: CC-3 & CC-4.
The quality assurance manual shall provide:

(a) Organization chart of quality assurance department.
(b) Qualification and experience details of the personnel of quality
assurance department.
(c) In-house quality control plan.
(d) Procedures and standards adopted for designing, manufacturing,

inspection / testing.
(e) Facilities available for inspection and testing including NDT.

(f) Quality check points indicating the customer hold points normally
adopted by him for such check points starting from raw material.
Procurement till final tests to be conducted and accepted at shop and
site.
(g) Mock-up test procedures.

Section: CC-6
1&2 Sheet 2 of 3
(h) Defect rectification or deviation acceptance procedure with regard to

approval by design department, by PURCHASER, by quality assurance
department and by collaborators including the information flow scheme
upto erection and commissioning department wherever applicable.
(i) On-line statistical quality control methods adopted to prevent defects in
mass produced items.
(j) Administrative procedure for corrective action (re-work) on defects.

3.0 The PURCHASER and/or his duly authorized representative shall have at all
reasonable times access to the Contractor’s premises or works and shall have
the power, at all reasonable times to inspect and examine the materials and
workmanship during manufacture and if part of the equipment is being
manufactured or assembled on other premises or works, the
CONTRACTOR shall obtain for the PURCHASER and / or his duly
authorized representative, necessary permission to inspect as if the
equipment were manufactured or assembled on the Contractor’s own
premises or works.
4.0 The PURCHASER or his representative shall have the right to inspect any
machinery, material, structures, equipment or workmanship furnished or used
by the CONTRACTOR and may reject any which is defective or unsuitable
for the use and purpose intended, or which is not in accordance with the
intent of the contract. The CONTRACTOR, upon demand by the
PURCHASER or his representative, shall remedy or replace at the
CONTRACTOR’s expense such defective or unsuitable items of the plant, or
the PURCHASER may, at the expense of the CONTRACTOR, remedy or
replace such defective or unsuitable items of the plant.
5.0 The PURCHASER or his representative shall at all working hours have
access to all parts of the Contractor’s and his SUB-Contractor’s factory
where the items of the plant are being prepared, and shall be provided with
all reasonable inspection facilities by the CONTRACTOR. The inspection
facilities shall include all necessary tools, instruments, equipment and
qualified operators to facilitate inspection. A set of latest prints of the
relevant approved drawings shall be made available by the CONTRACTOR
to the PURCHASER or his representative for reference during inspection.
6.0 For the purpose of this clause, inter works orders are to be treated as sub-
orders. It is obligatory on the CONTRACTOR that he advises his SUB-
CONTRACTOR of the pertinent clauses in this specification when ordering
bought-out equipment or materials. In particular, the CONTRACTOR is to
advise each SUB-CONTRACTOR that he is required to supply design
calculations, drawings, inspection reports and test certificates strictly in

Section: CC-6
1&2 Sheet 3 of 3
accordance with this specification and technical information for inclusion in

the instruction manual as specified in Section: C-0.
7.0 The CONTRACTOR will offer test reports on incoming material inspection,
for verification by Purchaser’s representative.
8.0 The CONTRACTOR is to provide test pieces as required by the Purchaser’s
representative to enable him to determine the quality of material supplied
under this contract. If any test piece fails to comply with the requirements,
the Purchaser’s representative may reject the whole material represented by
the test piece. The PURCHASER or his representative shall have the right to
select particular test piece of his choice from the lot in case of sample testing.
In case the results are found to be not satisfactory the Purchaser’s
representative shall have the right to test more number of pieces or each
piece additionally from the lot for testing or reject whole lot.
9.0 A typical Quality Control Plan is enclosed as Annexure-II.

Section: CC-7
1&2 Sheet 1 of 1
TENDER EVALUATION R1
NIL

Section: CC-8
Tender Document
Technical Specification For Power Batteries for KAPS-1&2 Sheet 1 of 3
TESTS AT SITE
R1
1.0 The following tests shall be conducted at site on station batteries

and accessories as per standards specified. These are however, not
intended to form a comprehensive commissioning check list as it
shall be the SUPPLIER's responsibility to draw up and carry out
such a program duly approved by the PURCHASER. Typical
checks to be carried out at site are listed in item 2.0 below:
2.0 TYPICAL CHECKS
The SUPPLIER shall arrange for necessary equipment for

carrying out these tests at site.
2.1 Preliminary checks
a) Check name plate details of every associated

equipment according to specification.
b) Check for physical damage.
c) Check for tightness of all bolts, clamps and

connecting terminals.
d) Check cleanliness of cells, stands, and battery installation.
e) Check for correct electrolyte level.
f) Check for electrolyte specific gravity.
g) Check for electrolyte leakage.
h) Check for chemical analysis of acid and water for mixing with
electrolyte and topping up.
i) Check for any cell container crack.
j) Verification of dimensions.
k) Verification of stands and cell mounting etc.

l) Verification of battery installation and terminations as per
drawings.

Section: CC-8
Tender Document
TESTS AT SITE
R1
m) Verification of inter-cell, inter-stand, inter- row connection

and measurement of their resistance.
2.2 Acceptance Tests
a) Visual inspection.
b) Verification of markings.
c) Tests for capacity (for duty cycle and C-10 discharge) and capability to
recharge.
NOTE: The battery shall initially on first charging be charged as per
manufacturer’s recommendation and subjected to few charge-
discharge cycles till 100% rated capacity assigned by manufacturer is
obtained.
1. Initial C10 discharge tests.
2. Test C10 discharge upto specified end of discharge voltage as

per standards.
3. Charge as per manufacturer's procedure
4. Discharge at high rate (as applicable for new battery including all
margins) till the specified end of discharge voltage.
5. Charge as per manufacturer's procedure.
margins) for specified duration.
7. Charge for 8 hrs. as specified.
margins) as above for specified duration.
9. Completely recharge the battery and keep on float after adjusting

electrolyte level in all cells to maximum position.

Section: CC-8
Tender Document
TESTS AT SITE
R1
d) Test for voltages both on bank and on pilot cells (1 out of each 6 cells)
during discharge.
e) Polarity and absence of short circuit.
f) Insulation resistance test.
g) Duty cycle discharge test on battery bank after float charge for three (3)
months.


Tender Document
1&2 Sheet 1 of 1
SPECIAL TOOLS AND TACKLES FOR ERECTION
AND MAINTENANCE R1
1.0 NAME PLATE REQUIREMENT
1.1 Battery tag details and rating plate shall be permanently attached to battery
room. Name plate shall be of 3-ply laminated non-corrodible laminated
plastic material with black lettering engraved onto a white background. Name
plate shall able to stand the prevalent atmospheric conditions as indicated. The
inscription shall be engraved in black on the plate.
1.2 The size of the rating plate shall depend upon space availability but should be
reasonably sized for clarity and clear inscription. The size of the plates and
inscriptions shall be approved by the PURCHASER. The plates shall be
attached to the body of the equipment by screws.
1.3 Each cell of the battery shall be marked in a permanent manner to indicate the
following information:
a) Manufacturer's name and trade name.
b) Type of battery.
c) Cell designation as per the relevant standard.
d) Type of positive plate.

e) Nominal Voltage.
f) Rated AH capacity at 10 hours rate.
f) Max. & Min marking for electrolyte level.

Section: CC-10
1&2 Sheet 1 of 1
LIST OF DRAWINGS R1
1.0 The following drawings are enclosed with the specification for the guidance of the
TENDERER. The offer shall be generally in conformity with these drawings.
SL. DESCRIPTION
NO.
(1) KAPS-1 POWER BATTERY ROOM LAYOUT
(2) KAPS-2 POWER BATTERY ROOM LAYOUT

Section: CC-11
Tender Document
LIST OF ANNEXUERES Sheet 1 of 1
R1
Annexure No. DESCRIPTION

Annexure-I Duty cycle Diagram
Annexure-II Sample QA plan.

Tender Document Section: D-1.0
Technical Specification For Power Batteries for KAPS- Sheet 1 of 9
1&2
TECHNICAL DATA
REVISION 1
Following data shall be furnished by the TENDERER along with his offer for the
batteries covered by this specification:
Sl. No. Description Suppliers Response
1.0 Make:
2.0 Type No./designation:
3.0 Type of cells offered
4.0 C10 AH Capacity of the battery offered

to meet the duty cycle requirement of
the specification.
5.0 Number of cells in each bank:
6.0 Correction factors considered while

calculating the AH rating of cells:
6.1 Temperature correction factor for

minimum ambient temp of 8 °C:
6.2 Aging margin:
6.3 Design margin:
6.4 Whether any correction factor for float
charging considered?
If yes , specify the value
6.5 Any other factor that needs to be
considered for properly sizing the
battery to meet the intent of
specification?
7.0 Design calculation enclosed for arriving

at C-10 AH rating? Yes/No:
8.0 Duration of discharge for new battery
while subjected to loading as per duty
cycle diagram & as per EOD voltage
specified in Section CC-3 in minutes:

1&2
TECHNICAL DATA
REVISION 1
9.0 Magnitude of current new cell is

capable of discharge for 30mnts before
reaching specified end of discharge
voltage (EOD).
10.0 Short circuit current from battery at

battery terminals:
a) Momentary short circuit current
(A):
b) Steady state short circuit current
(A):
c) Time constant:
(Furnish the graph showing the S.C
current vs time)
11.0 Charging Requirements
11.1 Float Charging:
11.1.1 Voltage (V):
11.1.2 Current (A):
11.1.3 H2 liberation rate(m3/hr)/A per cell:
11.2 Equalizing Charging:
11.2.1 Voltage (V):
11.2.2 Current (A):
11.2.3 H2 liberation rate(m3/hr)/A per cell:
11.2.4 Duration, procedure and frequency of

equalizing charge:
11.2.5 Criteria, for equalizing charging:
11.2.6 Current limit at which equalizing charge

should be carried out (A):
11.3 Boost Charging:

1&2
TECHNICAL DATA
REVISION 1
11.3.1 Recommended values for boost

charging voltage & associated current
limit in charger to ensure that battery is
fully charged in 8 hrs after the following
types of discharges:
a) High rate of discharge as

pespecified duty cycle (for 8 hrs.
recharge)
i) Voltage (V):
ii) Current limit (A):
b) C10 discharge (for lead acid
batteries).
i) Voltage (V)
ii) Current limit(A): Starting rate
iii) Current limit : finishing rate
11.3.2 H2 liberated (m3/hr):
11.3.3 Duration of boost charging (hrs):
11.3.4 a) Recommended Frequency of

Charge equalizing ( Quarterly/Half
yearly)
11.3.5 b) Recommended mode of
Equalizing(Constant
current/Constant Voltage)
11.3.6 c) Maximum Permissible Ripple
voltage and Current
12.0 Internal resistances of cell (ohms):
d) One typical cell(ohms)
e) Complete battery(ohms)
f) Cell to cell connector
g) Row to row connector

1&2
TECHNICAL DATA
REVISION 1
13.0 Terminal voltage of the battery bank

after considering voltage drops due to
internal cell resistances and inter cell
and inter row connectors resistances at
the end of following types of
discharges at 27°C:
a) Duty cycle discharge
b) C10 discharge for Lead Acid --- Volts

batteries.
--- Volts
14.0 Dimension and weights
14.1 Dimension of each cell
(mm x mm x mm):
14.2 Distance between cell centers when

erected (mm)
14.3 Weight of each cell

i) With electrolyte (kg):
ii) Without electrolyte ( kg):
14.4 Overall dimensions of battery bank (mm

x mm x mm):
14.4.1 Heat liberated into room during boost
charging.
14.4.2 Heat liberated into room at specified
high rate discharge.
14.5 Racks
14.5.1 Dimensions of each rack

(mm x mm x mm):
14.5.2 Weight of each rack (kg)
14.5.3 Tender drg. Showing layout of battery Yes / No

& all dimensions enclosed?
14.5.4 Whether racks are insulated from Yes / No

ground?

1&2
TECHNICAL DATA
REVISION 1
14.5.5 Material:
14.5.6 No. of cells per rack:
14.5.7 No. of racks in each bank:

14.5.8 Interval between topping up of cells
with distilled water (months):
15.0 AH efficiency (%):
16.0 Watt hour efficiency (%):
17.0 Whether the cells are dispatched

without electrolyte and max. period of
storage under this condition:
18.0 Positive plate
18.1 Type of construction:
18.2 Material:
18.3 Dimensions:
19.0 Negative plate
19.1 Type of construction:
19.2 Dimensions:
19.3 Material:
20.0 Grid
20.1 Material:
21.0 No. of positive plates per cell
22.0 No. of negative plates per cell
23.0 Thickness of positive plates before

forming(mm):
Thickness of negative plates before

forming(mm):

1&2
TECHNICAL DATA
REVISION 1
27.0 Weight of positive plate before forming

(kg):
28.0 Weight of negative plate before

forming (kg):
29.0 Terminal Posts Connector
29.1 Material
29.2 Thickness of lead coating(mm):
29.3 Cross sectional area(maximum)
30.0 Connectors
30.1 Material
30.2 Thickness of lead coating (mm)
30.3 Cross section area(maximum)
30.4 Whether connectors are designed

considering high discharge currents?
30.5 Max. temperature of connector or joints

permissible during high rate of
discharge.
31.0 Containers
31.1 Material:
31.2 Whether transparent

(Yes / No):
31.3 Container lid

a) Material
b) Method of fixing to the container
31.4 Height of sediment space provided

1&2
TECHNICAL DATA
REVISION 1
32.0 Whether identical type of battery with

racks have been previously type tested
to prove seismic withstand capability?
(If yes, type test report to be furnished
along with the response spectra)
33.0 For lead acid batteries, state whether
"ECO-mark" has been allotted by
Bureau of Indian Standards (Yes / No):
34.0 Separator
34.1 Material:
34.2 Type of separators
34.3 Amount of separator over lap provided
34.4 Applicable standards:
35.0 Electrolyte
35.1 Amount of electrolyte for first filling

(liter):
35.1 Amount of electrolyte per cell (liter):
35.3 Applicable standard for electrolyte:
35.4 Height of electrolyte above the plates

and below the min level indicated:
36.0 Battery terminal voltage on sudden

disconnection of float charger with load
connected (V):
37.0 Life of battery
37.1 State the expected design life of the

battery as per site ambient condition in
terms of No. of calendar years from the
date of commissioning.

1&2
TECHNICAL DATA
REVISION 1
37.2 Life of battery in terms of no. of C10

capacity discharges followed by boost
charging under the maximum ambient
conditions specified. i.e. specify no. of
C-10 tests battery bank can undergo in
its entire expected life period under
max. Ambient temp. Conditions.
37.3 Life of battery in terms of no. of Duty

Cycle test (High Rate Discharge i.e.
HRD) discharges followed by boost
charging under the maximum ambient
conditions specified. i.e. specify no. of
HRD tests battery bank can undergo in
its entire expected life period under
max. Ambient temp. Conditions.
38.0 Recommended minimum no. of air

changes to be provided in battery room:
39.0 Specific gravity of electrolyte at 27

deg.C. and with cell completely charged

deg.C. after duty cycle discharge

deg.C. after C10 discharge
42.0 Specific gravity of electrolyte 27

Deg.C. after 8 hr. of charging
subsequent to a duty cycle discharge.

Deg.C. after 12 hrs. of charging
subsequent to a C10 capacity discharge.
44.0 Whether all spares as specified included
in the scope? Include list of spares
considered.
45.0 Whether all maintenance accessories as
specified included in the scope?
Include list of maintenance accessories
considered?

1&2
TECHNICAL DATA
REVISION 1
46.0 Detailed calculation of battery sizing

including all margins to ensure battery
will give minimum backup of 30 min @
1007A DC and power battery bank
should also be capable of give DC back
up of 08 hrs. as per attached load duty
cycle (Annexure-I).

Tender Document Kakrapar Atomic Power Station Unit 1&2 Section: D-2.1
1&2 Sheet 1 of 1
SCHEDULE OF PROPOSED
EQUIPMENT MANUFACTURER'S
GENERAL PARTICULARS REVISION 1
NIL

SCHEDULE OF TENDERER’S Sheet 1 of 1
EXPERIENCE
REVISION 1
NIL

Tender document SECTION : D-2.3
DRAWINGS TO BE SUBMITTED
ALONGWITH THE TENDER SHEET 1 OF 1
Revision-1
As part of the proposal the TENDERER shall furnish the following for
preliminary study:
a) Panel general arrangement drawing showing plan, front view, and

foundation details, inside view, terminal block location etc.
b) Schematic wiring diagram of the panel.
c) Block diagram of the Battery Systems
d) Bill of material listing equipment designation, make, type, ratings of the

various equipment.
e) Detailed literature/catalogues for all equipment being offered under this

contract.
f) Any other drawings necessary for the correct and complete understanding of
the proposal.
NOTE All drawings and data shall be annotated in English.
SIGNATURE _________________
DESIGNATION _________________
COMPANY _________________
DATE _________________
SEAL OF COMPANY
SPECIFICATION NO. KAPS/52324/PB SEPC./001 Oct-2015

PERFORMANCE DATA, INCLUDING
PERFORMANCE CURVES, ETC. TO BE Sheet 1 of 1
SUBMITTED ALONGWITH THE TENDER
REVISION 1
The TENDERER shall confirm with design calculations and/or test certificates
that the equipment has been designed to meet seismic qualification requirement as
called for in section C-1.
DESIGNATION _________________
COMPANY _________________
DATE _________________
SEAL OF COMPANY

Section: D-2.5
Tender Document Schedule of submission of drawings, data,
instruction manuals, Test reports etc. Sheet 1 of 2
REVISION 1
The Contractor should furnish detailed schedule for submission of various documents,
manufacture, delivery, erection and commissioning of the equipment covered by this
specification.
Sl. No. Particulars Mention in

Days/Month
1.0 Preparation and submission of activity networks indicating
start and finish of various activities like preparation of
drawings, procurement of materials, manufacturing, type &
routine testing, delivery, removal of old system and
commissioning of new system at site etc.
2.0 Approval of Activity Network by Purchaser
3.0 Submission of following drawings from date of PO

3.1 General arrangement including plan, mounting arrangement of
equipment, cable connection, gland plates etc.
4.0 Preparation & Submission of Quality Assurance Plan (QAP)

5.0 Procurement of Raw Materials
6.0 Manufacturing of Battery cells and stands the purpose of type
testing including those for seismic test
7.0 Completion of Seismic Tests
8.0 Manufacture of complete equipment
9.0 Completion of routine and Type testing
10.0 Completion of Delivery, Not later than :
11.0 Erection, Testing & Commissioning

Section: D-2.5
Tender Document Schedule of submission of drawings, data,
instruction manuals, Test reports etc. Sheet 2 of 2
REVISION 1
Mention in
Sl. No. Particulars
Days/Month
12.0 INSTRUCTION MANUALS
The CONTRACTOR shall furnish specified no. of copies of

the instruction manuals which would contain detailed
instructions of all erection, testing, operation and
maintenance requirements and shall include the following
aspects :
12.1 Instructions manuals for erection, commissioning,
operation, maintenance of various equipment covered.
12.2 Complete bill of materials for all equipment and
accessories.
12.3 One complete set of drawings, in A3 size.
12.4 List of spares
12.5 Catalogues of all bought out components
13.0 END DOCUMENTATION
MANUFACTURER shall submit 10 (Ten) copies of end
documents in bound volumes. End documents shall contain
among others the following details :
13.1 Purchase order copy along with amendments issued if any
13.2 Copies of shipping releases issued
13.3 Copies of approved erection and commissioning procedures
13.4 Copies of approved design concession requests.
13.5 Final drawings
13.6 Complete set of factory test reports
13.7 Approved seismic qualification reports
13.8 Quality control plan, test procedures, stage wise inspection
reports etc.
13.9 Storage instructions
NOTE : Equipment shall not be despatched unless the test certificates are duly approved
by PURCHASER.
SIGNATURE ____________
DESIGNATION ____________
COMPANY ____________
DATE ____________
COMPANY SEAL
SCHEDULE OF PERFORMANCE
GUARANTEE Sheet 1 of 1
REVISION 1
The TENDERER shall furnish performance guarantee in respect of the following:
1.0 All equipment/accessories supplied shall conform to the requirements

listed in this specification as well as the requirements of all applicable
standards. Not meeting any of these requirements will result in rejection of
the equipment/accessories.
SIGNATURE ________________
DESIGNATION ________________
COMPANY ________________
DATE ________________
SEAL OF COMPANY
SPECIFICATION NO. KAPS/52324/PB SEPC./001 Oct-205

SCHEDULE OF DEVIATIONS Sheet 1 of 1
FROM TECHNICAL SPECIFICATIONS
REVISION 1
All deviations from the technical specification shall be filled in by the TENDERER
clause by clause in this schedule.
Section Clause No Deviation
The TENDERER hereby certifies that the above mentioned are the only deviations
from the technical specification of the enquiry.
SIGNATURE ________________
DESIGNATION ________________
COMPANY ________________
DATE ________________
SEAL OF COMPANY

Technical Specification for Electrical System Mega Package for KAPS-1 & 2.
1&2 Sheet 1 of 1
SCHEDULE OF MANUFACTURING,
DELIVERY AND OTHER RELATED
ACTIVITIES REVISION 1
The TENDERER shall indicate the time for manufacture, delivery and other activities
of each equipment as shown below:
Equipment Time from Time for works Time Total time Time for Time required
date of order test, required from date removal of old for erection,
to works test dismantling, for of order to battery banks testing and
packing & ready shipment receipt at and shifting it to commissioning
for despatch to site site store and of battery at
from works transporting to site.
suppliers works.
(Days) (Days) (Days) (Days) (Days) (Days)
KAPS-1
KAPS-2
We, the undersigned hereby undertake to meet the above time schedule
from the date of order.
SIGNATURE _____________
DESIGNATION _____________
COMPANY _____________
DATE _____________
SEAL OF COMPANY

1&2. Sheet 1 of 1
SCHEDULE OF PERSONNEL FOR ERECTION
TESTING AND COMMISSIONING REVISION 1
The tenderer shall indicate below the number and category of personnel required for
erection, start-up and performance testing and commissioning.
Category Erection Testing & Commissioning

Number Number
Expatriate Local Expatriate Local
Personnel Recruitment Personnel Recruitment
The tenderer shall also indicate here those section of works or items for which specialist
services on site are required.
SIGNATURE _____________
DESIGNATION _____________
COMPANY _____________
DATE _____________
SEAL OF COMPANY

K#1 Battery Room Layout
K#2 Power Battery Room Layouts
Sample QUALITY ASSURANCE PLAN FOR 354 V DC LEAD ACID POWER BATTERIES (SAMPLE)
ANNEXURE – II
SL. COMPONENT CHARACTER- CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. AND ISTIC CHECK OF CHECK DOCUMENT NORMS OF
OPERATION RECORD
P W V
1. POSITIVE
PLATE
a. Antimonial Analytical C Chemical Every Batch Manufacturer’s TC 2 2,3 1

lead Analysis Manufacture Document
b. Spine alloy Analytical C Chemical Twice per Manufacturer’s TC 2 2,3 1

Analysis week
r’s Document
c. Casting Weights/ B Visual Check/ 2/3 times per Document Manufacturer’s TC 2 2 1

Dimension Measurement shift Document
d. Cutting & Physical B Visual Check Once per Manufacturer’s TC 2 2 1

guilloting day Manufacturer’s Document
Document
e. Oxide filling Physical B Weight Every shift Manufacturer’s Manufacturer’s

Document Document TC 2 2 1
Manufacturer’s
Document
Manufacturer’s
Document
Page 1 0f 11
OPERATION RECORD
P W V
2. NEGATIVE
PLATES
a. Grid Alloy Analytical C Spectrophotom Twice Manufacturer’s TC 2 2,3 1

-etricl Analysis Manufacturer’s Document
Document
b. Grid Dimensional B Visual check/ per week Manufacturer’s TC 2 2 1
Casting Measurement Manufacturer’s Document
Document
Analytical C Chemical Manufacturer’s TC 2 2,3 1
c. Oxide Analysis 2/3 times per Manufacturer’s Document
shift Document
d. Paste Process Control C Density/ Daily Manufacturer’s TC 2 2 1

mixing/ Weight Manufacturer’s Document
Pasting of Document
flat
Plates Per mix 2/3
times per
Process Control C Visual/ shift Manufacturer’s TC 2 2 1
e. Curing, Chemical Manufacturer’s Document
Formation Document
Daily
Page 2 0f 11
NO. AND ISTIC CHECK OF CHECK DOCUMENT NORMS OF RECORD
OPERATION
P W V
3. Separators Physical / C a. Electrical Every Manufacturer’s IS 6071 Manufacture 2 2 1
Dimensional / prodn. Document r Record
Electrical Resistance Run book TC
C Manufacturer’s IS 6071 Manufacture 2 2 1

b. Pore size Once in 3 Document r Record
months book TC
C Manufacturer’s IS 6071 Manufacture 2 2 1

c. Volume Once in 3 Document r Record
Porosity months book TC
C IS 6071 IS 6071 Manufacture 2 2 1

d. Cl/Fe/Mn Once in a r Record
Content year book TC
C IS 6071 IS 6071 Manufacture 2 2 1

e. Life Test Once in a r Record
year book TC
Page 3 0f 11
OPERATION RECORD
P W V
4. Containers Verification of Type & Visual check/ Sample As per approved As per approved TC 2 2,1 1 CHP
construction accepta- Measurement drawing drawing
requirement nce test
Verification of Type & Visual Sample IS 1146 IS 1146 TR 2 2,1 1 CHP

marking & accepta-
packing nce test
High Voltage Type & Electrical IS 1146 IS 1146 IS 1146 TR 2 2,1 1 CHP
test routine
test
Drop ball Type test Mechanical IS 1146 IS 1146 IS 1146 TR 2 2,1 1 CHP
Acid resistance Type test Chemical IS 1146 IS 1146 IS 1146 TR 2 2,1 1 CHP
Plastic yield Type test Mechanical IS 1146 IS 1146 IS 1146 TR 2 2,1 1 CHP
Bulging test Type test Physical Once IS 1146 IS 1146 TR 2 2,1 1 CHP
Bulging test at Type test Physical Once Approved test Approved test TR 2 2,1 1 CHP
55 deg. C (with procedure procedure
water)
Page 4 0f 11
OPERATION RECORD
P W V
5. Terminal post Dimensional B Visual 1% of lot Manufacturer’s Manufacturer’s TC 2 2 1
drawing drawing
Electrical C Conductivity 1% of lot Manufacturer’s Manufacturer’s TC 2 2 1

Physical drawing drawing
6. Inter cell/ Dimensional B Visual 1% of lot As per approved As per approved TC 2 2 1

Row connector drawing drawing
(applicable only
for rigid Conductivity C Electrical 0.1% of lot As per approved As per approved TC 2 2 1
connectors and drawing drawing
cable lugs)
Analytical C Chemical 0.1% of lot As per approved As per approved TC 2 2,3 1
Analysis drawing drawing
Heat & Quench C PB-Sn coat 1% of lot ASTM B-571 ASTM B-571 TC 2 2 1
test
Peel test C Adhesion 1% of lot ASTM B-571 ASTM B-571 TC 2 2 1
Page 5 0f 11
OPERATION RECORD
P W V
7. Terminal take Dimensional B Visual 100% As per approved As per approved TR 2 2,3, 1
off drawing drawing 1
Arrangement
Electrical C Conductivity 1% As per approved As per approved TC 2 2 1
drawing drawing
8. Dimensional B Visual/ 100% of lot As per relevant As per relevant TR 2 2,1 1

Battery Racks Measurement drawing drawing
Assembly
Physical C Mech. Each lot As per relevant As per relevant TR 2 2,1 1

Property IS Spec IS Spec
Welding B 10% of lot Approved procd. Approved procd TR 2 2,1 1
-
Analytical C Each lot As per relevant As per relevant TR 2 2,1 1
Chem. Spec. Spec.
Property
Page 6 0f 11
OPERATION RECORD
P W V
8.1 Painting Pretreatment, C Process Test coupon NPCIL Spec. NPCIL Spec. TR 2 2,1 1 CHP
painting, shade PC-E-246 PC-E-246 (to be
of painting conducted
on test
Pretreatment C Process Test coupon PC-E-246 PC-E-246 Inspection 2 1,2 1 coupon)
check report ,, ,,
Bend (flexibility Type Mechanical Clause No.2 IS-101 IS-101 TR 2 2,1 1 ,, ,,

test) test of IS-101
Pull off Type Physical Clause No.5 IS-101 IS-101 TR 2 2,1 1 ,, ,,

(adhesion) test Test of IS-101
Painting B Measurement Sample NPCIL Spec NPCIL Spec TR 2 2,1 1 ,, ,,

thickness check PC-E-246 PC-E-246
Page 7 0f 11
OPERATION RECORD
P W V
9. Fasteners Dimensional B Visual 1% of lot As per relevant - TC 2 2 1

drawing
10. Buffers, vent Dimensional/ B Visual 1% of lot As per relevant Inspection/ TR 2 2 1

plugs, grommets Material drawing Manufacturer’s
shrouds, cell no. certificate
plate
11. Assembly of cell Physical C Visual 100% Conforms to Inspection work TC 2 2 1

material list
12. Acid Analytical C Chemical Every IS 266 IS 266 TR 2 2,3 1

analysis supply
13. Acid level Dimensional/ C Visual 1% of lot As per relevant - TC 2 2 1

indication Material drawing
Page 8 0f 11
OPERATION RECORD
P W V
14. Water Analytical C Chemical Every IS 1069 IS 1069 TC 2 2,3 1
Analysis supply
15. Interconnecting Routine test B Electrical 100% IS-10810 IS-10810 TC 2 2,3 1

cables
16. Assembly of
plates and
separators
a) Welding of Physical C 2 samples As per approved As per approved Log book 2 2,1 1
plates with group per set drawing drawing
bar Complete
cell
Visual C 2 samples As per approved As per approved Log book 2 2,1 1
b) Clearance per set drawing drawing
between plates
and separator
Physical C 2 samples As per approved As per approved Log book 2 2,1 1
c) Tightness of per set drawing drawing
cell assembly
strap
Physical C 2 samples As per BOM As per BOM Log book 2 1,2 1
d) Placing of per set
plate assembly in
container
correctly
Page 9 0f 11
OPERATION RECORD
P W V
17. Complete cell Cleanliness Routine Visual 100% IS 1651 IS 1651 TR 2 2,1 1 CHP
Verification of Type test Visual IS 8320 IS 1651 IS 1651 TR 2 2,1 1 CHP

construction
Verification of Type & Visual IS 8320 IS 1651 IS 1651 TR 2 2,1 1 CHP

marking & Acceptance
packing test
Verification of Type & Measurement IS 8320 Approved Approved TR 2 1,2 1 CHP

dimension Acceptance drawing drawing
test
Test for C10 & Type test & Electrical IS 8320 IS 1651 IS 1651 TR 2 2,1 1 CHP
C1 capacity and Acceptance
voltage during test
discharge
Ampere-Hr and Type test Electrical Sample IS 1651 IS 1651 TR 2 2,1 1 CHP
Watt-hour
efficiency test
Test for loss of Type test Electrical Sample IS 1651 IS 1651 TR 2 2,1 1 CHP
capacity on
storage
Page 10 0f 11
SL. COMPONENT CHARACTER- CLASS TYPE OF QUANTU REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. AND ISTIC CHECK M OF DOCUMENT NORMS OF RECORD
OPERATION CHECK
P W V
Test for Type test & Electrical IS 1651 NPCIL Spec NPCIL Spec. TR 2 1 1 CHP
suitability of Acceptance
floating battery test
operation
Endurance Test Type test Electrical IS 1651 IS 1651 IS 1651 TR 2 1,2 1 CHP
Short ckt current Type test Electrical IS 1651 IS 1651 IS 1651 TR 2 1,2 1 CHP
and internal
resistance test
Water loss test Type test Electrical IS 1651 IS 1651 IS 1651 TR 2 1,2 1 CHP
18. Packing Soundness Routine Visual 100% NPCIL Spec. NPCIL Spec. IQC format 2 2,1 1 CHP
19. Documents Completeness B Review 100% NPCIL Spec. NPCIL Spec. NPCIL QS 2 2,1 1 CHP
format
20 Complete test Special test As Special test Electrical As per As per CC-5 As per CC-5
per CC-5 clause- CC-5 clause-16.9 of clause-16.9 of TR 2 2,1 1 CHP
16.9 of spec. and clause- spec. and CC-3 spec. and CC-3
CC-3 clause-1.6 16.9 of clause-1.6 clause-1.6
spec. and
CC-3
clause-1.6
LEGEND
P : Performed by A : Minor 1 : Purchaser
W : Witnessed by B : Major 2 : Prime Supplier
V : Verified by C : Critical 3 : External Laboratory
TC : Test Certificate
TR : Test Report
CHP : Customer’s Hold Point
Page 11 0f 11

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KAKRAPAR ATOMIC POWER STATION

UNITS 1 & 2 (220 MWe)

PROCUREMENT SPECIFICATION NO. KAPS/52324/PB SEPC./001

SPECIFICATION FOR POWER BATTERIES

Prepared By: Checked By: Reviewed By: Approved By:

Kapil Mishra Ulhas Pethkar P. Barik S K Deshmukh V K Sharma

Document No: KAPS/52324/PB SEPC./001

Title: Specification for Power Batteries of KAPS

(Kakarapar Atomic Power Station-1 & 2)

Rev. No. Date Description of Prepared by Checked By Reviewed by Approved by

KAKARAPAR ATOMIC POWER STATION

SPECIFICATION No.: KAPS/52324/PB SEPC./001 Oct-2016

SECTION TITLE NO.OF SHEETS

CC-1 Scope of Supply/Work/Services 3

CC-2 Applicable Codes, Standards and Specifications 2

CC-3 Specification of Main Equipment and Accessories 5

CC-4 Equipment Construction & Design Details 12

CC-5 Inspection & Testing 8

CC-6 Quality Surveillance 3

CC-7 Tender Evaluation 1

CC-8 Tests at Site 3

CC-9 Special Tools & Tackles for Erection & Maintenance 1

CC-10 List of Drawings enclosed 1

D. FORMAT FOR SUBMISSION OF PART I (TECHNICAL)

D2.1 Schedule of proposed equipment manufacturer’s

D2.2 Schedule of Tenderer’s Experience 1

D2.3 Drawings to be submitted along with the Tender 1

D2.4 Performance Data, including performance curves, etc. to be 1

D2.5 Schedule of submission of drawings, data, instruction manuals, 2

D2.6 Schedule of Performance Guarantee 1

D2.7 Schedule of Deviations from Technical Specifications 1

D2.8 Schedule of Manufacturing, delivery and other related activities 1

D2.9 Schedule of Personnel for Erection, Testing & Commissioning 1

SPECIFICATION No.: KAPS/52324/PB SEPC./001 Oct-2015

2 52324-BY-2 Tubular battery (TBS- Lead acid cells TB-1 & 2

SPECIFICATION NO: KAPS/52324/PB SEPC./001 July-2013

SPECIFICATION NO: KAPS/52324/PB SEPC./001 July-2013

SPECIFICATION NO: KAPS/52324/PB SEPC./001 July-2013

Kakrapar Atomic Power Station Unit 1&2 Section: CC-2

1.0 The design, material, construction, manufacture, inspection, testing and

3.0 Other National Standards are acceptable if they are established to be

2) IS:1069 Quality tolerances for water for storage

3) IS:1146 Rubber and plastic containers for lead-acid

4) IS:1651:2013 Stationary cells and batteries, lead-acid type with

SPECIFICATION NO: KAPS/52324/PB SEPC./001 Oct-2015

Kakrapar Atomic Power Station Unit 1&2 Section: CC-2

5) IS:1885 Electrotechnical vocabulary: (Part VIII)

6) IS:3116 Sealing compound for lead-acid batteries.

7) IS:4905 Methods for random sampling.

8) IS:6071 Synthetic separators for lead-acid batteries.

11) IEEE:450 Recommended practice for maintenance, testing

12) IEEE:484 Recommended practice for installation design

13) IEEE:485 Recommended practice for sizing large lead

14) IEEE:535 Standard for qualification of Class-1E lead

SPECIFICATION NO: KAPS/52324/PB SEPC./001 Oct-2015

Technical Requirements for Lead Acid Batteries:

SR. DESCRIPTION POWER BATTERIES

(c) Float charging Up to 400 V DC

1.4 Cell voltages

1.4.2 Equalizing voltage considered 2.4 VPC

1.4.3 Max. Boost voltage considered

SPECIFICATION NO: KAPS/52324/PB SEPC./001 Oct-2015