OFFSHORE SPEC. No.

FS 4023
DESIGN SECTION: FUNCTIONAL
ENGINEERING SPECIFICATION Rev. No. 2
SERVICES FOR
ISO – 9001:2000 BATTERY & Discipline Elect
BATTERY CHARGER Page: 1 of 10

FUNCTIONAL
SPECIFICATION
FOR
BATTERY & BATTERY CHARGER

PREPARED / REVISED REVIEWED APPROVED TOTAL NO. OF DATE REV.

BY BY BY PAGES
BR LNVR RK 12 1
SRS AS HMG 10 20/02/08 2

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 2 of 10

1. SCOPE

This specification defines the requirement of the battery and battery charger system
required to be installed on offshore platforms. Batteries shall meet the requirements of
loads listed in attached data sheet.

2. CODES & STANDARDS

2.1 All batteries, battery chargers and their accessories supplied shall comply with the
requirements of the latest revisions of the relevant standards of :

ISI INDIAN STANDARDS INSTITUTION

IEC INTERNATIONAL ELECTRO-TECHNICAL COMMISSION
BSI BRITISH STANDARDS INSTITUTION
NEMA NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION
NEC U.S. NATIONAL ELECTRICAL CODE
IEEE INSTITUTE OF ELECTRICAL & ELECTRONICS ENGINEERS
API AMERICAN PETROLEUM INSTITUTE

2.2 Any other recognized international codes or standards may be followed in lieu of
above with prior approval of the Company.

3. SITE CONDITIONS

All the equipments shall be designed and tropicalised to withstand the site conditions as
specified in General Design Criteria enclosed in the bid package.

4. SCOPE OF SUPPLY

The scope of supply includes:

4.1 Nickel- Cadmium battery bank, racks and accessories.

4.2 Battery charger panel
4.3 Ni-Cr plated double compression type brass cable glands and tinned copper lugs.
4.4 Any other components or accessories, if not mentioned specifically, but considered
essential to make the system complete for safe and reliable operation shall be
included in the contractor’s scope of supply.

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
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5. TECHNICAL REQUIREMENT

5.1 GENERAL

5.1.1 The battery charger, battery and specified auxiliary components shall be the
products of firms regularly engaged in the manufacture of these items and shall
meet the requirements of this specification.

5.1.1 All materials and parts comprising part of the equipment specified herein shall
be new and unused, of current manufacture, of the highest grade and free from
all defects and imperfections that could adversely affect the performance of the
system.

5.2 SAFETY

It is the intent of the purchaser that operational hazards be reduced to minimum.

The vendor shall use good engineering judgment in providing equipment to
complete an installation that could perform the required function without
compromising on safety. All controls shall operate in fail-safe-mode.

5.3 BATTERY CHARGER

5.3.1 Two chargers shall serve each battery assembly. Each battery assembly shall
comprise of two Nos. battery packs each rated 50% by amp. hour capacity and
suitable for full voltage level.

5.3.2 Normal operation will require that the battery assembly will be float charged by
both chargers while feeding the D.C. loads, thus working in parallel to each
other. In case of failure of either of the chargers, the other will float charge the
battery assembly while supplying the complete D.C. load. The faulty charger
shall get disconnected from the healthy system automatically. In case of A.C.
Mains failure, the battery assembly shall supply the load automatically without
any break and shall stop feeding the load as soon as AC mains supply is
restored.

5.3.3 These chargers shall also boost charge ½ of the battery assembly as and when
required. The charging will be off-line i.e. while disconnected from the charger
supplying the D.C. load and float charging the remaining ½ of the battery
assembly. It shall be possible to boost charge each of the battery section in
either “manual” or “auto” mode. In auto-mode, boost charging shall be

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
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automatically initiated when the battery charging current demand increases. In

this situation, the rectifier shall go into current limit. If this situation persists
beyond a preset time, the rectifier shall be switched on to boost charging. The
system shall return to float charging after the preset time, or when the
auto/manual selector switch is turned to manual position and float/boost selector
switch is pushed into float position. In manual mode, boost charging shall take
place and continue for the preset time. The system shall return to float charging
after the pre-set time, or if float/boost selector switch is pushed back to float
position.

5.3.4 The design of each of the chargers shall be identical and rating of either charger
shall be selected for the worst case of duty out of the following:

5.3.4.1 Off line boost rate charging of ½ of the battery assembly from a discharge
state to fully charged state in 10 hrs.
5.3.4.2 On line float charging of the complete battery assembly (both ½ sections
connected in parallel) plus supplying the complete DC load.

5.3.5 Battery charger (s) shall be sized based on the nominal rated capacity of the
battery. Complete battery charger system including rectifier, battery, and static
switches, etc. shall have 10% spare capacity for future load growth.

5.3.6 The battery chargers shall conform to the requirements specified in the data
sheets attached. The battery chargers offered shall be of solid/state design.
Design features must include electronic compensation to limit regulation effects
due to either line voltage variation for load and temperature change. A 30
millivolt filtering shall be provided in chargers for batteries of 48 V or less and
100 millivolt filtering shall be provided in chargers for batteries above 48 V.
Battery charger shall be of the constant voltage with current limit type with
protection against reverse battery connections and open circuit on the output.
The battery charger shall be provided with Audio Visual alarms as per the data
sheet. The chargers shall be provided with facilities for load sharing, load
balancing and for paralleling of the incoming charger with the charger already
on load, without any system disturbance. Blocking diode protection and/or
current limiting protection shall be provided for all electronic circuits. A battery
voltage sensor shall be included to prevent overcharging of batteries. The
battery charger shall have surge suppression resistors both on AC & DC sides.
Wherever required, silicon dropper diodes shall be provided in the battery. To
prevent both batteries being boost charged simultaneously further interlock shall
ensure that before switching one charger to the boost position, the second

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 5 of 10

charger shall be in its float charge condition and shall be supplying power to the
DC output. Timer (0-24 hours) for automatic changeover of the modes from
boost to float shall be provided with bypass features. The interlocking device
shall inhibit one charger from being switched into boost charging when,

5.3.6.1 The other charger is being switched into boost charging either manually or
by the automatic device during normal operation.
5.3.6.2 The battery circuit breaker of the other system is tripped.

5.3.7 Battery charger shall be mounted in an enclosure with minimum degree of

protection, IP-41 suitable for use in a pressurized building and also capable of
with standing the tropical marine environment of the site. Painting shall be done
as per General Specification – Protective Coatings (Spec. No. 2005). Enclosures
shall have front access and shall be suitable for floor mounting.

5.3.8 Each rectifier unit shall have an incoming AC circuit breaker and outgoing DC
circuit breaker feeding DC bus. The bus shall be adequately sized and rated for
the conditions specified. The bus joins shall be bolted. Bus insulation shall be
flame retardant. The incoming DC breakers to DC bus shall have suitable shunt
trip coils. The main DC bus shall feed the DC Distribution board through circuit
breaker. The circuit breakers shall be moulded case type and suitable for
prospective fault levels. AC incoming side of bus chamber and outgoing DC
circuits shall be segregated from one another. Necessary termination accessories
shall be included in the contractor’s scope of supply. Cable entry shall be from
bottom of panel. The complete panel shall be suitable for operation and
maintenance from front only.

5.3.9 2.5 mm2 PVC insulated copper wire, 600 volt rated, shall be used for control
wiring and 0.75 mm2 PVC insulated copper wire shall be used for electronic
circuitry. Wiring to door mounted devices particularly, shall be stranded. Wire
lugs shall be crimping type. Bundles of wires shall be routed neatly in vertical
or horizontal planes. Individual wires of bundles shall be secured with PVC
wire ties, cable lacing or by enclosing in PVC wire trays. All components and
all insulation shall be treated to prevent fungus growth. All terminal blocks shall
be rated 16 amperes (minimum) at 600 volts. All terminal blocks shall have
white PVC marking strip throughout the length of the block. Each block shall
have 10% spare terminals. All wiring shall be identified by permanent slip-on or
clip-on marking sleeves on each terminating wire in addition to the mark on the
block.

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
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5.3.10 Nameplates shall be 3-ply, white-black-white, 2 colour, and laminated plastic.

Lettering shall have 5mm minimum height, and edges shall be bevelled at 450.

5.3.11 A space heater along with adjustable setting thermostat shall be provided inside
the battery charger cabinet for driving out moisture contents. The circuit shall be
connected through MCB and separate terminals for connecting A.C. supply for
space heater “ON” condition.

5.4 BATTERY

5.4.1 BATTERY BANK

The batteries shall be of Ni-Cd cells of nominal voltage specified in the Data
sheet. The battery shall be supplied with high impact translucent plastic
enclosures for visual electrolyte inspection and shall have flame arresting
recombination vent. Battery bank capacity in Ah shall be adequate for the
specified load and site conditions. Depth of discharge (DOD) of 100% and
ageing factor of 0.8 shall be taken into consideration while sizing. The end cell-
voltage after discharge shall be limited to 1.1 volt per cell. The battery shall be
such that there will be minimum water loss during charging due to evaporation.
The discharge performance of the battery shall be compatible with the
envisaged load cycle. Batteries shall be suitable to withstand at least 1600
charge/discharge cycles involving 70% DOD. Each battery bank shall have 10%
spare capacity for future load growth.

5.4.2 BATTERY RACKS

Battery racks shall be PVC lined steel frame rack with cells installed on PVC
lined trays. The battery rack shall be complete with all support and tie down
equipment. Arrangement requiring minimum space shall be provided. The rack
assembly once assembled shall be shock and earthquake proof to Zone IV as per
IS: 1893 and suitable for installation on offshore structure. The rack design shall
be selected considering following factors.
- Space on the offshore platform is limited.
-
Lower weight is preferred.
-
Ease of maintenance of mounted cells.
(The arrangement shall be such that minimum space is required for installation).

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
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5.4.3 CONNECTORS

Suitable tinned copper links for inter-cell and inter-row connectors with PVC
sleeving and end take-offs shall be provided with clamping terminations. Care
shall be taken to overcome bimetallic corrosion. The terminal connection shall
be anti-loosening against vibration. These shall be suitable for the salt laden
marine environment. If more than one battery banks are proposed to achieve
required loads or voltages, cables for interconnection shall be included in
vendor’s scope of supply.

5.4.4 TOOL KIT AND BATTERY ACCESSORIES

Vendor shall furnish a lockable steel box complete with accessories as

mentioned below:

- Two (2) Hydrometers for electrolyte specific gravity readings.

-
Assorted connectors , lugs, nuts, and vents,
-
One (1) Cell testing voltmeter.
-
Two (2) Pairs rubber hand –gloves.
-
Two (2) Aprons.
-
Six (6) Spanner nut wrenches.
-
One (1) Electrolyte pouring funnel.
-
Two (2) Thermometers.
-
Four (4) Level testers.
-
One (1) No. spare Cell
-
Acid/ Alkali resistant jugs and funnels, eye protection devices (goggles).
Vendor shall also furnish the required quantity of electrolyte, plus 10% extra in
non-returnable containers. Warning labels and instruction manuals for
operation, maintenance and installations shall be included in vendor’s scope of
supply.

6. TESTING AND INSPECTION

All tests shall be carried out as per relevant standards at vendor’s works. In case the
actual battery to be supplied is not available, tests may be conducted using identical
alternate battery supply. Testing and inspection of battery/charger system shall include
but not necessarily be limited to the following:

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
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6.1. A visual inspection shall be made to ensure that good workmanship and practices
were maintained throughout fabrication and assembly.
6.2. A quantitative check shall be made to ensure that all items in specified quantities
are present according to the purchase specifications and packing list.
6.3. A functional test shall be conducted with all controls and alarms for correct setting
and operation.
6.4. Capacity and load cycle test for battery.
6.5. Testing and calibration of all indicating instruments.
6.6. Insulation resistance test of all wiring
6.7. Burn out test on battery charger for 100 hours.
6.8. If the tests show that certain requirements of this specification are not met, vendor
shall make necessary corrections to the equipment before offering it for acceptance
so that it satisfies all the requirements.
6.9. Company reserves the right to have a representative to witness tests performed and
request corrective action, wherever necessary.
6.10. Vendor shall notify Company twenty days prior to testing. Vendor shall furnish test
date and location to Company for decision on exercising its right to witness the test.

7. SPARES

7.1. Vendor shall provide spare parts needed for start-up. In addition, vendor shall also
furnish a separate priced list of recommended spares for two (2) of normal
operation and maintenance. Recommended spares shall take into account the related
factors of equipment reliability, effect of equipment downtime upon production,
safety and cost of parts and availability of equipment service facilities.

7.2. All spares furnished by vendor shall be wrapped and packaged so that they will be
preserved in original as new condition under the normal conditions of storage
prevailing in India and shall be properly tagged to facilitate future and coded
identification as to intended equipment usage will be facilitated. They shall be
packaged separately, clearly marked as “Spare Parts” and shipped along with the
main equipment. Packing lists shall be furnished so that the parts can be handled
without uncrating, if desired.

8. WARRANTY

Vendor shall have final and total responsibility for the design and performance of all the
batteries, battery chargers and their accessories supplied under this specification. Any
defects discovered during warranty period shall be rectified free of charge. The warrantee
/ guarantee from the contractor’s side to this effect shall be governed by the warranty /

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 9 of 10

guarantee clause mentioned in the general terms and conditions of contract and special
conditions of contract.

9. VENDOR DATA REQUIREMENTS

Vendor shall furnish the following data/information related to the battery sets and
chargers.

9.1. Arrangements drawings with outline dimensions including clearance requirements.

9.2. Electrical details

- Equipments details
- Mounting details
- Completed data sheet
- Battery and charger sizing calculations
- Calculation for selection of dropper diodes on load terminals

9.3. Electrical wiring

- Schematic diagrams
- Single line diagram

9.4. Electrical reference material

9.4.1. General Description

9.4.2. Performance data, catalogues, brochures and certified test reports.
9.4.3. Part list & Bill of materials
Bill of materials should as minimum, contain following information/details in
respect of each component of the battery charger-
(a) Name of component
(b) Rating
(c) Type/Model Reference
(d) Quantity installed
(e) Part No.
(f) Manufacturer’s Name and address.

9.4.4. Circuit breaker operation curves

9.4.5. Recommended spare parts with prices
9.4.6. Code certificates
9.4.7. Operating and maintenance instructions

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 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
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10. CERTIFICATION

All the offered batteries, battery chargers and their accessories or those of similar design
and construction features manufactured by same vendor:

• shall have been type tested by an authority approved by the Company.

• shall have been in continuous satisfactory service in off-shore for a minimum
period of two years.
• shall be having current certification/approval/listing by an approved agency or UL
or FM.

11. PACKING & TRANSPORTATION

The offered batteries, battery chargers along with their accessories, shall be shipped to
site packed in wooden crates. They shall be wrapped with polythene sheets, before being
placed in the crates to prevent damage to finish. Crates shall have skid bottom for
handling.

12. ATTACHMENTS

The following documents shall form part of this specification.

2005 PROTECTIVE COATING

DS 4023 DATA SHEET

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