GUJARAT STATE ELECTRICITY CORPORATION LIMITED · (a) Battery of 220 V, 1300 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 1300

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SIGN AND SEAL OF BIDDER

GUJARAT STATE ELECTRICITY CORPORATION LIMITED

TECHNICAL SPECIFICATIONS FOR

TUBULAR / VRLA TYPE LEAD ACID BATTERY SET

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I N D E X

CLAUSE NO. TITLE PAGE NO. Special Instruction to Bidder 03 Qualifying Requirement of Bidder 04

SCHEDULE-B General Technical Specification 1.0 Scope 05 2.0 Applicable Standard 05 3.0 General Requirement 06 4.0 Accessories 09 5.0 Guaranteed Technical Particulars 10 6.0 Quality Assurance Plan 11 7.0 Drawing and Data 11 8.0 Instruction Manuals 12 9.0 Packing 12 10.0 Test 12 11.0 Inspection of Equipments 13 12.0 Guarantee 14 13.0 Deviations 14 14.0 Commissioning 14

ANNEXURE-B Detail Scope Of Work 15 SCHEDULE-A Requirement of Battery 19

ANNEXURE-A1 List of Accessories-Ukai TPS 20 ANNEXURE-A2 List of Accessories-Ukai HPS and Mini Hydro 21 ANNEXURE-A3 List of Accessories-Dhuvaran CCPP-I/II 22 ANNEXURE-A4 List of Accessories-Sikka TPS 23 ANNEXURE-A5 List of Accessories-KLTPS 24 ANNEXURE-A6 List of Additional Accessories-For Each Station 25 ANNEXURE-A7 Existing Arrangement of Battery Sets 26

Schedule of Guaranteed Technical Particulars 33

(This document is meant for exclusive purpose of bidding against this specification and shall not transfer, reproduced or otherwise used for purposes other than that for which it is specifically issued.)

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SPECIAL INSTRUCTIONS TO BIDDER

Please read following instructions carefully before submitting your bid. 1. All the drawings, i.e. elevation, side view, plan, cross sectional view etc., in

AutoCAD format and manuals in PDF format, for offered item shall be submitted. Also the hard copies as per specification shall be submitted.

2. The bidder shall submit Quality Assurance Plan for manufacturing process and

Field Quality Plan with the technical bid. 3. The bidder shall have to submit all the required type test reports for the offered

item. In case of non-submission of the type test reports with the offer, the bid shall be liable to be rejected.

4. The bidder must fill up all the point of GTP for offered item/s. Instead of

indicating “refer drawing, or as per IS/IEC”, the exact value/s must be filled in. 5. All the points other than GTP, which are asked to confirm in technical

specifications must be submitted separately with the bid. 6. The bidder is required to impart training in view of manufacture, assembly,

erection, operation and maintenance for offered item, at his works, to the person/s identified by GSECL, in the event of an order, free of cost. The cost of logistics will be bear by GSECL.

7. Please note that the evaluation will be carried out on the strength of content

of bid only. No further correspondence will be made. 8. The bidder shall bring out all the technical deviation/s only at the specified

Annexure. 9. The bidder should indicate manufacturing capacity by submitting latest

updated certificate of a Chartered Engineer (CE).

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QUALIFYING REQUIREMENT OF BIDDER

Bidder to satisfy all the following requirements-

1. The bidder shall be Original Equipment Manufacturer (OEM). The offered equipment have to be designed, manufactured and tested as per relevant IS/IEC with latest amendments.

1A.-Bidders not meeting the requirements at 1 above but authorized by OEM having qualifying requirement as per 1 above can also participate, provided they have valid ongoing collaboration with manufacturer. In such an event the bidder shall furnish, along with his bid, documentary evidence for the same and an undertaking from the bidder and collaborator accepting joint and several liabilities of all the obligations under the contract.

2. The bidder should have executed such type of supply and work as per tender specification in past and bidder have to submit documents conforming the same during last three years in utilities like State Electricity Corporations, NTPC, PGCIL etc.

3. The minimum requirement of manufacturing capacity of offered type, size and rating of equipment shall be 7 times tender / bid quantity. The bidder should indicate manufacturing capacity by submitting latest updated certificate of a Chartered Engineer (CE).

4. Equipment offered shall be of similar or higher rating and in service for a minimum period of FIVE (5) years and satisfactory performance certificate from utilities like State Electricity Corporations, NTPC, PGCIL etc. in respect of this should be submitted.

5. The bidder should clearly indicate the quantity and Single Value Contract executed during last FIVE (5) years, for the offered equipment. Bidder should have executed one single contract during last five years for the quantity equivalent to tender / bid.

The details are to be submitted in following format-

Sr. No

TEMS SUPPLIEDTO

ORDER REFERENCE No. and DATE

ITEMS QUANTITY ORDER FULLY EXECUTED YES/NO

STATUS, IF ORDER UNDER EXECUTION

REMARK

6. Equipment offered shall have Type Test Certificates from accredited laboratory (accredited based on ISO/IEC Guide 25 /17025 or EN 45001 by the National accreditation body of the country where laboratory is located), as per IEC / IS / technical specifications not older than FIVE (5) years and valid till validity of offer.

7. The bidder shall guarantee for supplying maintenance spares and services of equipments and accessories for a period of the life expectancy of 10 years.

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SCHEDULE-B GENERAL TECHNICAL SPECIFICATIONS

TUBULAR / VRLA TYPE LEAD ACID BATTERY SET

1.0 SCOPE: 1.1 This specification covers the design, manufacture and testing of Tubular /

VRLA type lead acid battery set at the manufacturer's works and supply, installation, commissioning at site. It also includes supply of FRP stand and all accessories mentioned in this specification. Detail scope of work is at Annexure-B.

2.0 APPLICABLE STANDARDS: 2.1 Unless otherwise specified in this specification, the lead acid batteries shall comply with the following standards and latest amendments revision thereof.

SR. NO. STANDARD DESCRIPTION 1 IEC 60896-21/

22:2004/Part-II

General requirements and methods of tests for Stationary lead acid batteries.

2 IS: 1885 Electrical vocabulary – Stationary cells and batteries.

3 IS: 1651 Specification for stationery cells and batteries lead acid type with Tubular positive plates.

4 IS: 1146 Specification for hard rubber and plastic containersfor lead acid storage batteries.

5 IS: 6071 Specification for synthetic separators for lead acid Batteries

6 IS: 652 Specification for wooden separators for lead acid batteries.

7 IS: 266 Specification for sulphuric acid 8 IS: 1069 Specification for water for storage batteries 9 IS: 3116 Specification for sealing compound for lead acid

batteries. 10 IS:8320 General requirements for methods of tests for lead

acid storage batteries. 11 IEEE - 485 IEE recommended practice for sizing of large lead

acid storage batteries for generating stations and sub stations.

12 IEEE-484 Recommended practice for design and installation of storage batteries.

13 IS15549:2005 VRLA Batteries 14 IEEE1188/118915 TEC:GR/BAT-

01/03, MARCH 2004

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3.0. GENERAL REQUIREMENT:(1) Most versatile in discharge, which requires that it can supply very high current

on instant demand and at same time are capable of providing low current for extended periods.

(2) Mainly stored energy of battery is released on failure of main power supply, therefore extremely high standard of reliability and its safety is required over an extended period of useful life.

(3) High pressure spine casting of Electrodes to ensure uniform and consistent grain orientation and no voids in spine.

(4) High quality lead (99.97 % pure). (5) Less Antimony content (Less than 3 %) to ensure low float charges current and

therefore low electrical consumption throughout its service life on float operation.

(6) Polyethylene envelope separator to eliminate the possibility of side short circuit.

(7) Global quality standard as per ISO: 9001 is preferable. (8) Type Test approved by ERTL or such Govt. recognized Lab. (9) AH Efficiency at rated load should be more than 90% and WH Efficiency

should be more than 75%. (10) Gasification Voltage, internal resistance, short circuit capacity, design

parameters etc. should be as per relevant standard. (11) Initial and Rated Capacity of Battery at 27 degree Centigrade should be

required AH. (12) Chemical composition of positive plate is lead antimony alloy spine

surrounded by PbO2.(13) Chemical composition of negative plate is special Lead Antimony alloy (14) Containers material should be hard rubber. (15) Vent plug material should be dome type ceramic. (16) Working height of the battery set along with stand should be 1000 mm (plus

or minus 10 %) from ground level. 3.1 The batteries shall be suitable for a long life under continuous float operations

at 2.15 to 2.25 volts per cell and occasional discharges and shall be stationary Lead Acid type with High Discharge Performance (HDP) confirming to IS mentioned at Clause No. 2.1 (latest edition) suitable for Indoor operation.

3.1.1 The batteries shall be of the capacity mentioned at Schedule-A as per requirement of tender.

(a) Battery of 220 V, 1300 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 1300 Ampere Hours capacity at 10 hours discharge rate.

(b) Battery of 220 V, 500 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 500 Ampere Hours capacity at 10 hours discharge rate.

(c) Battery of 220 V, 300 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 300 Ampere Hours capacity at 10 hours discharge rate.

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(d) Battery of 220 V, 800 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 800 Ampere Hours capacity at 10 hours discharge rate.

(e) Battery of 372 V, 360 AH rating shall consist of 186 numbers of series connected Sealed Maintenance Free Valve Regulated Lead Acid (VRLA) cells of 2.0 Volts, having 360 Ampere Hours capacity at 10 hours discharge rate.

(f) Battery of 125 V, 400 AH rating shall consist of 63 numbers of series connected HDP lead acid cells of 2.0 Volts, having 400 Ampere Hours capacity at 10 hours discharge rate.

(g) Battery of 220 V, 1000 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 1000 Ampere Hours capacity at 10 hours discharge rate.

(h) Battery of 220 V, 600 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 600 Ampere Hours capacity at 10 hours discharge rate.

3.2 Charge rate- 3.2.1 Fully discharged batteries get recharged at 10 % (of AH Capacity) Amps

rate for 10 hours at room temperature. The trickle charge rate shall be 50-100mA.

3.3 DETAILS OF BATTERY SET: 3.3.1 The cell container shall confirm to latest edition of IS:1146. The cell container

shall be made from non porous Hard Rubber or polypropylene or transparent SAN copolymer. The material shall have chemical and electrochemical compatibility and shall be acid and heat resistant. The container and cover shall be capable of withstanding the rigorous of transport, storage and handling and shall be free from flaws. Sufficient space for sediments shall be provided. It should have adequate Mechanical strength to prevent bulging, cracking etc. during the life span of battery when operating under expected temperature range and due to action of static and dynamic loads and the action of electrolyte.

3.3.2. The plates shall be designed for maximum durability during all service condition including high rate of discharge and rapid fluctuations of load. The construction of plates shall confirm to latest revision of IS:1651.

(i) The positive plates shall be of Tubular Type. Plates shall be made of high pressure (not less than 50 Kg/cm2) cast special Lead Antimony alloy spines in complete contact with superior active material, effectively retained in multi-tube woven gauntlet of high tensile acid-resistant polyester and shall be free from any kind of manufacturing defects. Plates shall be made of 99.99% pure lead and shall be free from any kind of manufacturing defects. It shall be electrochemically formed and shall be capable of operating under normal working condition without buckling or cracking. The positive plates should be cast in a single piece. Welding together of smaller size lead casting/plates to form larger sizes will not be acceptable. It should be genuine Tubular type of plate only and not so called equivalent type.

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(ii) The negative plate shall be of flat pasted type and made of special Lead Antimony alloy. It should have adequate mechanically strength and should be so designed that active material is maintained in intimate contact with the grid under normal working conditions throughout life of battery.

3.4 The plates shall be separated by a low resistance absorbent micro porous glass fiber/Polyethylene (PE) mat. The separators shall be compressed sufficiently to maintain ‘separator to plate contact’ throughout the life of the cell. The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. The separators should be of High Porosity polyethylene envelope form permanent insulating diaphragms between the plates. It should be acid resistance, chemically inert and should have excellent oxidation resistance and high degree of porosity to ensure low electrical resistance. It should not exhibit any tendency to swell or shrink at temperature encountered during operation.

3.5 The inter-cell, inter-row, inter-tier, end takeoff connectors and lugs for cable shall be of lead plated copper. The lead coating shall be adequate and tenacious. Minimum thickness of lead coating shall be 30 microns. The lead plating shall be effective to prevent corrosion. The cross section of the connectors/lugs shall have adequate area and shall offer minimum impedance to carry the high currents i.e. they shall be capable of continuously carrying the 30 minute discharge current of the respective batteries and shall be capable to carry 4 KA for 1 sec. The connectors shall be adequately designed to withstand various stresses due to temperature changes, attack of acid, dynamic forces that could occur during operation of the battery and short circuit conditions. However, the thickness of these connectors shall, in no case, be less than 6.5 mm. The nos. and dimensions of connectors shall be stated in the GTP and in the drawing. Suitable mechanical supporting arrangements for end takeoff terminals to be provided so as to avoid extra load on battery terminals. All cell terminals shall have adequate current carrying capacity. Connectors should be adequately designed to offer minimum impedance. While considering the terminal voltage of the cell at the time of testing for discharge, the voltage drop due to inter-row and inter-cell connectors shall be considered.

3.6 The electrolyte shall be battery grade sulphuric acid conforming to latest edition of IS: 266 and distilled water confirming to IS: 1069. Required quantity of electrolyte for the initial filling with 10% extra quantity shall be supplied in non-returnable, non-degradable acid resistant strong plastic containers. Diluted sulphuric acid of approved quality and required quantity shall be supplied in separate non-returnable porcelain or any other acid and corrosive proof jars.

3.7 Positive and negative terminal posts of the cells shall be clearly and unmistakably identifiable. Terminal posts shall be designed to accommodate external bolted connections conveniently and positively. All metal parts of the terminals shall be of lead or lead coated type. Bolts, heads and nuts, except seal nuts, shall be hexagonal and shall be lead covered. Terminal posts shall be adequately fixed to prevent its turning or twisting when the connectors are being fixed or removed. The junction between terminal posts

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and cover shall be adequately sealed to prevent any seepage of the electrolyte. All terminals shall be provided with insulated covers (Shrouds).

3.8 Each cell shall be provided with ceramic type vent plug. It shall be anti-splash type, having more than one exit hole and shall allow the gases to escape freely but shall prevent acid from coming out. Each cell shall be provided with acid and oxidation proof float type level indicators with marking for the electrolyte level for upper-lower-normal limits.

3.9 For VRLA Type Battery: Valve regulated venting device of each cell shall be provided with flame arrestors to prevent any sparking flame from entering the cell.

3.10 The Battery stand for supporting battery cells shall be provided. The construction of the stand shall be suitable for mounting on a flat concrete floor. The stand shall be rigid, free standing type and free from wrap and twist. The stand for battery cell shall be manufactured from best quality seasoned teak wood finished with at least three coats of anti-sulphuric paints of approved shade. Suitable porcelain / plastic insulators shall be provided between the stand and the battery room floor. Number plate (no sticker) to designate each cell of battery shall be provided and shall be attached on the rack. Provision shall be made for clamping outgoing cable on the rack. The stand should be designed considering all aspect of loading and safety, so as to withstand the loading of battery set throughout its life, which shall be supported by load bearing calculation. The cell shall be supported on the rack in suitable row and tier formation with adequate clearance between adjacent cells. The lower tier of the stand will be at the height of 300 mm from the ground level. Support angle should be provided for each rack so as to safeguard each battery cell from falling or declining. There shall be sufficient space, at least 400 mm, between two tiers of stand so that maintenance of battery cells of lower tier can be done easily. Necessary supports for power cable connected to end takeoff terminals shall be mounted on the stand. Requirement is as under:

SR. NO. PLACE STAND 1 UKAI TPS SINGLE TIER 2 UKAI HPS SINGLE TIER3 UKAI MINI HYDRO DOUBLE TIER4 DHUVARAN SINGLE TIER5 SIKKA SINGLE TIER6 KLTPS SINGLE TIER

3.11 The arrangement of cell for tubular type battery should be required such as to meet following requirement-

(a) The inter cell distance: minimum 25 mm. (b) The inter row distance: minimum 600 mm.

4.0. ACCESSORIES:

The bidder shall supply the battery with accessories and devices as per Annexure-A1, A2, A3, A4, A5 for various power stations and Additional Accessory requirement as per Annexure-A6.

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5.0 GUARANTEED TECHNICAL PERTICULAR: SR. NO.

SPEC. UKAI TPS

UKAI HPS

UKAI MINI

HYDRO

DHUVARAN SIKKA KLTPS

SCHEDULE-A : SR.NO. 1 2 3 4 5 6 7 81 Capacity at 10

hrs rate (AH) 1300 500 300 800 360 400 1000 600

2 Total voltage for the complete set (V-DC)

220 220 220 220 372 125 220 220

3 Nominal voltage per cell of fully charged battery at 27ºC (V-DC)

2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0

4 Voltage at end of discharge per cell at 27ºC (V-DC)

1.85 1.85 1.85 1.85 1.85 1.85 1.85 1.85

5 Type of cell HDP TUBULAR VRLA HDP TUBULAR 6 Type of Battery LEAD ACID 7 Type of Stand WOODEN 8 Quantity of

cell(Nos.) 110 110 110 110 186 63 110 110

9 Specifications IS 1651-LATEST IS 15549-2005

IS 1651-LATEST

10 Condition of Supply

DRY UNCHARGED CHARGED

DRY UNCHARGED

11 Antimony Content

< 3 % < 3 % < 3 % < 3 % < 3 % < 3% < 3 % < 3 %

12 Gasification Volt per Cell (V)

2.36 2.36 2.36 2.36 2.36 2.36 2.36 2.36

13 Ampere-Hour Efficiency

> 90 % > 90 % > 90 % >90 % >90 % >90 % >90 % >90 %

14 Watt-Hour Efficiency

> 75 % > 75 % > 75 % >75 % >80 % >75 % >75 % >75 %

15 Specific Gravity of Electrolyte (a)First Filling (b)Full Charge (c)After C10

Discharge

(a) 1.190 +/- 0.005 at 27° C (b) 1.200 +/- 0.005 at 27° C

(c)1.120 +/- 0.015 at 27° C

16 Construction Details of Plates-(a)Positive (b)Negative

(a) TUBULAR (b) FLAT PASTED

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17 Open circuit voltage (OCV) of fully charged battery at an average 27 ºC(V)

2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2

18 Recommended Float Charging Condition (a) Voltage of

charger (V) (b) Charging

Current (A)

(a)245(b) 1 to

4

(a)240(b) 30

to 35

(a)240(b) 15

Asper IS

As per IS

As per IS

As per IS

(a) 240 (b) 105

19 Recommended Float Charging Condition (a) Voltage of

charger (V) (b)Charging

Current (A)

(a)302(b)140

-70

(a)240(b) 35

to 40

(a)240(b) 45

Asper IS

As per IS

As per IS

As per IS

(a) 302 (b) 105

6.0 QUALITY ASSURANCE PLAN: Bidder shall submit the Manufacturing Quality Plan showing all the details along with the offer. 7.0 DRAWINGS AND DATA: 7.1. The bidder shall submit along with their offer the following drawings in Hard

and soft copy- (i) Set of GA Drawing for complete battery sets, battery stand and individual

battery cell drawing with sectional view. (ii) Technical literature/Manuals (iii) Performance curves/write-up on working of battery. The Data submitted shall

be adequate to evaluate the performance/quality of item offered. 7.2.The successful bidder shall submit three sets of following drawings for approval

in hard and soft copy- (i) Set of GA Drawing for complete battery sets, battery stand and individual

battery cell. (ii) Compete bill of material accessories indicating make, material, quantity, size

and type wherever applicable. (iii) Sectional view showing interior construction of the battery cell. It shall also

include the information of C/S area of positive and negative plates, container dimensions, type/grade and quantity of electrolyte.

(iv)The detailed drawing showing the size and quantity of steel sections for FRP stand.

(v) Technical literature/Manuals covering manufacturer’s instructions for filling and initial charging of the battery together with starting and finishing charging rate, maintenance instructions and storage conditions of electrolyte and battery cells.

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8.0 INSTRUCTION MANUALS :

8.1 Three (3) copies of operation, maintenance and erection manuals in English language for each type of battery shall be supplied, by the successful bidder, one month prior to the dispatch of the battery set to the Chief Engineer (Generation), Gujarat State Electricity Corporation Limited, Corporate Office, Vadodara and Three (3) copies each to the Chief Engineer(Generation), Gujarat State Electricity Corporation Limited, Ukai TPS/DHUVARAN/SIKKA/KLTPS.

8.2 The manuals shall be bound volumes and contain all the drawings and information required for erection, operation and maintenance of the battery set.

9.0 PACKING:

9.1 Battery shall be supplied in dry and uncharged condition suitably packed,

securely in wooden crates. Packing shall be suitable for handling during transit by Rail / Road and secured to avoid any loss or damage during transit.

10.0 TESTS: 10.1 The bidder shall submit the complete type test reports as stated hereunder

for the offered item along with the offer otherwise the offer shall be liable to be rejected. These tests must have been conducted in the Govt. approved laboratory as per IS 1651:1991, IS 15549:2005 and IEC 60896 – II within last 5 years prior to date of validation of the offer.

(A) For Tubular Lead Acid Type: (i) TYPE TESTS:- (a) Verification of constructional requirements (As per IS 1652). (b) Verification of marking and packing (As per IS 1652). (c) Verifications of dimensions (As per IS 1652). (d) Capacity test (As per IEC 60896) (e) Charge Retention Test (As per IEC 60896) (f) Endurance in discharge – charge cycles (As per IEC 60896) (g) Endurance in overcharge (As per IEC 60896 – II) (h) Test of suitability for floating battery operation (As per IEC 60896) (i) Short circuit current and internal resistance Test (As per IEC 60896) (j) Ampere- hour and watt-hour efficiency tests (As per IS 1652). (k) Test for voltages during discharge (As per IS 1652). (ii) ACCEPTANCE TESTS:- Tests shall be carried out as under at Manufacturer's works: (a) Visual inspection including marking and packing. (b) Dimensional check. (c) Capacity test. (d) Test for voltage during discharge. (e) Battery Impedance Measurement Test.

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NOTE: (1) Battery Impedance Measurement Test shall also be the routine test to be

taken at the site and Signature Value (Battery Impedance) of all the cells shall invariably be submitted after commissioning the battery set at the site.

(2) The acceptance test certificates shall be submitted for approval, before dispatch of the battery sets in bound volume. Also one set shall be submitted and sent with battery set.

(B) For Valve Regulated Lead Acid Type: (i) TYPE TESTS:- (a) Visual examination (As per IS 15549). (b) Verifications of dimensions as per drawing (As per IS 15549). (c) Capacity (C1 and C10) test (As per IS 15549) (d) Charge Retention Test (As per IS 15549) (e) Endurance Life cycles Test (As per IS 15549) (f) Ampere- hour and watt-hour efficiency tests (As per IS 15549). (g) Acid retention capability test on separators (As per IS 15549). (h) Wicking test on separators (As per IS 15549). (i) Test on vent seal operation (As per IS 15549). (j) Test for oxygen recombination efficiency (As per IS 15549). (k)Test of suitability for floating battery operation (As per IEC 60896). (l) Short circuit current and internal resistance Test (As per IEC 60896). (ii) ACCEPTANCE TESTS:- Tests shall be carried out as under at Manufacturer's works: (a) Visual inspection including marking and packing. (b) Dimensional check. (c) Capacity test. (d) Test for voltage during discharge. (e) Battery Impedance Measurement Test. 11.0 INSPECTION OF EQUIPMENTS :

11.1 Bidder shall have to arrange for inspections and routine tests on battery set at their works in presence of GSECL Engineer. Material will be offered for inspection before 15 days.

11.2 GSECL Engineer will not inspect incomplete materials. If GSECL Engineer returned without inspections of offered equipments, due to non-readiness of materials at their works. The financial loss to the Board, for deputing Engineer representative will be recovered from the concerned supplier.

11.3 The delivery period will be reckoned from the date of 100% receipt of material or equipment and not from the date of part supply.

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12.0 GUARANTEE : The bidder shall give assurance for trouble free and maintenance free performance for a period of 18 months from the date of receipt at store or 12 months from date of commissioning whichever is earlier during which period, items shall be repaired/reconditioned/replaced free of cost, immediately in case of any trouble.

13.0 DEVIATIONS: Bidder shall clearly bring out Technical Deviations separately mentioning the specification clause nos. against which deviations have been sought for and justifications for deviation. It shall be supported by authentic documents, standards and clarification. GSECL at their discretion will decide regarding acceptance of deviation.

14.0 COMMISSIONING: The first commissioning of each battery set at site shall be in the scope of the Bidder. The successful Bidder shall have to carry out first commissioning of each battery set at site. The successful bidder shall arrange for all the necessary equipment, including the variable resistor, tools, tackles, and instruments.

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ANNEXURE - B DETAIL SCOPE OF WORK

(A) Dismantling of existing DC Battery Sets-1. Due to installation of new Battery sets, if any modification required in existing

charger in control circuit during commissioning of battery sets, it will be in the scope of Bidder.

2. Bidder has to completely dismantle the existing Battery Set located at various battery rooms.

3. Before starting of dismantling work, necessary clearance for carrying out said work will be given by EMD engineer after confirming proper isolation from system. However Bidder has to confirm proper isolation from system prior to start of work.

4. Necessary power and control cables are to be disconnected. While disconnection, proper marking is to be carried out so that same can be re-commissioned with the new battery set.

5. All inter connection / links which are connected to existing battery set, to be disconnecting safely.

6. After complete disconnection from the system, the battery set is to be dismantling from the Foundation.

7. The dismantled battery set is to be shifted to the main store by the Bidder. Transport facility will be provided by GSECL free of charge as per availability. Bidder has to arrange for the same if not available with GSECL.

8. Bidder has to clean the site after complete dismantling of existing battery set so that work of erection of new battery set can be started without any delay.

9. The removed electrolyte is not to dispose anywhere in the plant as per norms of ISO -14001 and same is to be neutralizing at D.M. plant of GSECL with prior permission from the Chief Chemist. All necessary arrangement for shifting of electrolyte with due care from site to D.M. plant is to be done by the Bidder. If the same is not dealt carefully it will be viewed seriously and GSECL may take any action including cancellation of work order.

(B) Erection, Testing and Commissioning of New Battery Set- 1. Arrangement of FRP stand and locating cells on stand etc work is to be

arranged by Bidder. 2. Shifting of cells, Electrolyte, standard accessories etc. and unpacking of cells,

physical verification of cells etc is to be carried out by Bidder. 3. 1st Charging of cells is to be carried out as per standard procedure for

installation and commissioning of OEM and taking reading thereof. 4. Checking of charger healthiness, connection of Nuts and bolts, filling of

Electrolyte etc work is to be arranged by Bidder. 5. Adjusting of Specific gravity/voltage and levels as per requirement. 6. Submission of record and report of charging-in triplicate. 7. Special end connector of suitable size to terminate cable at battery end is to

be provided by the Bidder without any extra cost. 8. Required Man power and other materials are to be arranged by Bidder at his

own cost. No material will given by GSECL.

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9. Electrical supply and Air pipe connection will be given for above work free of cost by GSECL at one point.

10. Tools and special arrangement required for the job will be arranged by the

Bidder. 11. The work has to be done and completed as per full satisfaction of EIC. 12. Acceptance Test comprising Dimensional Test, Visual Test and Full Discharge

test (Capacity Test-C10) is to be carried out by the Bidder after initial charging and result of the tests/ Test -Certificates is to be submitted to the EIC by the Bidder before putting sets in to service.

13. Equalizing of the cells is to be done by the Bidder as per OEM guidelines. 14. Battery set installation shall be done by using the insulated tools and safety

wearing. 15. After installation of rack the individual cells are to be connected into group.

Connection may be made with interlinks connector. The Connectors and battery terminals contacts must be clean with suitable chemicals. For tightening the terminal screw with the correct torque, only torque spanners with socket may be used. When insulated connectors to be put, care has to be taken during assembly to avoid the clamping of plastic parts between conductive metal parts lying on one another. An appropriate check shall be done to check that there is slight play between the plastic cover caps and plastic insulation of the connectors when they are moved gently to and from in a horizontal direction. After the individual cells have been interconnected by means of connectors, the individual row, levels and tiers are connected. For group connectors only approved cable types should be used.

16. The wiring of the group and end connectors should be proof against short circuit. This means that the wiring used should have a dielectric strength of at least 3 KV or else an air gap of at least 10 mm should be maintained between the wire and electrically conductive parts. Alternatively, additional insulation may be used. Any mechanical loading of the end terminal is to be avoided by the fixing of the group and end connectors. The connectors ensure the optimal flow of current and therefore require perfect contacts.

17. Filling of Electrolyte: Bidder must ensure the quality and quantity of Electrolyte, so the battery must give the optimum performance during charging and discharging.

18. Commissioning of the battery: Before commissioning the battery vendor must ensure all safety instructions related to Lead Acid battery. General Instructions on Commissioning of the Battery shall be following as per Engineering practice during Charging and discharging.

19. The existing battery room dimensions- (1) Ukai TPS - approximately 30.0 feet long x 22.0 feet wide (2) Ukai Hydro – approximately 36.6 feet long x 31.4 feet wide (3) Ukai Mini Hydro – approximately 20 feet long x 13 feet wide (4) Dhuvaran CCPP – approximately 40 feet long x 18 feet wide (5) SIKKA TPS - approximately 26.5 feet long x 12 feet wide (6) KLTPS - approximately 28.5 feet long x 24.5 feet wide

20. The existing battery set arrangement is attached at Annexure-A7.

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(C) TERMS AND CONDITION: 1. Buy-back offer from the bidders are invited for existing battery sets as

mentioned below- SR.NO. PLACE EXISTING BATTERY DETAILS QTY OF CELL

1 UKAI TPS 220 V DC, 1300 AH HDP Tubular type Lead Acid battery

110 NOS.

2 UKAI HPS 220 V DC, 500 AH HDP Tubular type Lead Acid battery

110 NOS.

3 UKAI MINI HYDRO 220 V DC, 300 AH HDP Tubular type Lead Acid battery

110 NOS.

4 DHUVARAN 220 Volt, 725 AH HBL make Ni-Cd 180 NOS. 5 372 Volt, 360 AH HBL make VRLA

SMF 186 NOS.

6 125 Volt, 380 AH HBL make Ni-Cd 100 NOS. 7 SIKKA TPS 220 Volt, 1000 AH AUTOBAT make

HDP Tubular type 110 NOS.

8 KLTPS 220 Volt, 600 AH BUI make SPG600 110 NOS.

Bidder may visit GSECL site, if required, on any working day between 15.00 to 17.00 Hrs with prior permission of competent authority, to access the existing system before submitting their offer.

2. The equipment covered by this specification is a very important source of power supply for a power plant and hence should be of high quality and reliability. The bidder shall preferably be ISO- 9001 and ISO-14001 approved.

3. The bidder shall be financially stable and the following documents shall be submitted by the bidders with the bid.

(a) Last three years annual reports (b) List of plants and machineries installed in the works of bidder relevant to

equipment in the bid (c) Details and range of product manufactured. 4. Bidder shall offer the price for supply with Erection, Testing and Commissioning

of the battery set including dismantling of the old battery set. 5. Bidder has to arrange necessary man power for dismantling of old battery set

and erection, testing, commissioning of new battery set. Bidder has to depute trained and experienced commissioning engineer and employee for the subject work. GSECL will depute one Engineer for supervision of work.

6. Bidder has to arrange all necessary tools and tackles for erection, testing and commissioning work. If any special testing kit is required, than bidder has to arrange the same on its own. Necessary tools for lifting and shifting will be provided by GSECL free of cost as per availability. Bidder has to arrange for the same if not available with GSECL.

7. All Materials and consumable items required for subject work has to be arranged by the bidder at his own cost.

18


8. The bidder has to complete dismantling of old battery set, erection, testing and commissioning work of new battery set (01 set) within 15 days.

9. If at any stage, bidder fails to arrange for carrying out the work within notice period, the same will be carried out through outside agency at the risk and cost of the bidder and payment will be deducted from bidder bill.

10 The payment will be made after successful erection, testing and commissioning of above battery sets. The bidder will have to submit the bill in triplicate. Payment will be released as per GSECL`s rules and regulation after satisfactory completion of work.

11. For any ambiguity or conflict the decision of Chief Engineer, GSECL, TPS shall be final and binding to the bidder.

12. Bidder shall comply with the factory act/labor laws and safety law in force from time to time. Bidder persons shall strictly observe all safety norms and safe methods of working. Bidder shall take care to prevent any type of accident for safety of his persons. GSECL will not be responsible for any fatal or nonfatal accident to bidder’s person and for legal complications thereafter during work.

13. GSECL will provide facilities of Electrical power at one point free of cost. 14. For commissioning team, accommodation shall be provided on the

chargeable basis if available and local transportation arrange by the party. 15. Bidder has to take all necessary precaution during subject work so that no

damage to the GSECL property takes place. GSECL shall recover the cost in the event of any damage to its property.

19


SCHEDULE-A REQUIREMENT OF BATTERY

SR. NO.

BATTERY PARTICULARS POWER STATION QTY TYPE RATING

1 TUBULAR LEAD ACID

220 V,1300 AH UKAI TPS 01 SET = 110 CELL

2 TUBULAR LEAD ACID

220 V, 500 AH UKAI HPS 01 SET = 110 CELL

3 TUBULAR LEAD ACID

220 V, 300 AH UKAI MINI HYDRO 01 SET = 110 CELL

4 TUBULAR LEAD ACID

220 V, 800 AH DHUVARAN CCPP 01 SET = 110 CELL

5 VALVE REGULATED LEAD ACID

372 V, 360 AH 01 SET = 186 CELL

6 TUBULAR LEAD ACID

125 V, 400 AH 01 SET = 63 CELL

7 TUBULAR LEAD ACID

220 V,1000 AH SIKKA TPS 01 SET = 110 CELL

8 TUBULAR LEAD ACID

220 V, 600 AH KLTPS 01 SET = 110 CELL

20


ANNEXURE-A1 (UKAI TPS) LIST OF ACCESSORIES

SR. NO. ACCESSORY QTY 1 Inter Cell Connector 01 Set 2 Inter Bank Connector 01 Set3 Inter Raw Connector 01 Set4 Fasteners 01 Set5 Micro Porous Ceramic Vent Plugs 01 Set6 End Cell Takeoffs 04 Nos. 7 Lead Washer 01 Set8 Cell Support Insulators 01 Set9 White Petroleum Jelly 05 KG

10 Cell Number Plate(No Sticker) with fixing pins 110 Nos. 11 Level Indicating Floats 01 Set 12 Cell Electrolyte(Specific Gravity 1.200)-to commission

battery set As per

requirement 13 Mercury Glass Thermometer (0-100ºC) having suitable

scale representing 1ºC temperature rise and Gravity correcting scale with wall mounting teak holder

02 Set

14 Syringe type Hydrometer, showing specific gravity (1100-1300) in step of 0.005 with wall mounting teak holder

02 Set

15 Cell Testing Voltmeter [(-)3-0-(+)3] DC Volt)](0.05 V resolution)-As per IS:1248(Latest edition)

02 Nos.

16 Cell Testing Digital Voltmeter 3-1/2 digit LCD screen 02 Nos. 17 Wooden stand 01 Set 18 Insulated spanner set 02 Nos. 19 Plastic Syringe-10 oz 02 Set 20 Acid resistance funnel-Dia=6 inch (150 mm) 02 Set 21 Rubber Syphone- Dia=0.5 inch (12.7mm), L=2 meter long 02 Set 22 Rubber Glows 02 Set 23 Rubber Apron 01 No. 24 Acid resisting plastic jugs (2 Litre capacity) 02 Nos. 25 Rubber boots Knee height 02 Pair 26 Spare cells for above set with lid 04 Nos. 27 Rubber Mate-1 Meter x 0.5 Meter x 10 mm thick 10 Nos. 28 Instruction manual 02 Set 29 Operation and Maintenance manual 02 Set30 Battery bank characteristic curves 02 Set

NOTE: (1)Any item not specified above but which is required for commissioning and efficient working of the batteries may be supplied without any extra cost. (2) Accessories like inter cell connection inter- bank connector, vent plugs, fasteners, support insulators, electrolyte, jelly etc are to be supplied 10 % extra for replacement against damage during transit, handling, erection and commissioning activities as per Annexure-5.

21


ANNEXURE-A2 (UKAI HPS AND UKAI MINI HYDRO) LIST OF ACCESSORIES

(FOLLWING SAME SET EACH FOR UKAI HPS AND UKAI MINI HYDRO)



complete battery set As per



02 Set


02 Set


02 Nos.


NOTE: (1)Any item not specified above but which is required for commissioning and efficient working of the batteries may be supplied without any extra cost. (2) Accessories like inter cell connection inter- bank connector, vent plugs, fasteners, support insulators, electrolyte, jelly etc are to be supplied 10 % extra for replacement against damage during transit, handling, erection and commissioning activities as per Annexure-5

22


ANNEXURE-A3 (DHUVARAN CCPP-I/II) LIST OF ACCESSORIES

(SAME SET FOR EACH TYPE OF BATTERY AS PER REQUIREMENT)



battery set As per

requirement 13 Mercury in Glass Thermometer (0-100ºC) having suitable

scale representing 1ºC temperature rise and Gravity correcting scale

02 Nos.


02 Set


02 Nos.

16 Cell Testing Digital Voltmeter 3-1/2 digit LCD screen 02 Nos. 17 Wooden stand 01 Set 18 Insulated spanner set 02 Nos. 19 Plastic Syringe-10 oz 02 Set 20 Acid resistance funnel-Dia=6 inch (150 mm) 02 Set 21 Rubber Syphone- Dia=0.5 inch (12.7mm), L=2 meter long 02 Set 22 Rubber Glows 02 Pair 23 Rubber Apron 01 No. 24 Acid resisting plastic jugs (2 Litre capacity) 02 Nos. 25 Rubber boots Knee height 02 Set 26 Spare cells for above set with lid 04 Nos. 27 Rubber Mate-1 Meter x 0.5 Meter x 10 mm thick 10 Nos. 28 Instruction manual 02 Set 29 Operation and Maintenance manual 02 Set30 Battery bank characteristic curves 02 Set


23


ANNEXURE-A4 (SIKKA TPS) LIST OF ACCESSORIES



battery set As per



02 Set


02 Set


02 Nos.



24


ANNEXURE-A5 (KLTPS) LIST OF ACCESSORIES

SR. NO. ACCESSORY QTY 1 Inter Cell Connector 01 Set 2 Inter Bank Connector 01 Set3 Inter Raw Connector 01 Set4 Fasteners 01 Set5 Micro Porous Vent Plugs 01 Set6 End Cell Takeoffs 04 Nos. 7 Lead Washer 01 Set8 Cell Support Insulators 01 Set9 White Petroleum Jelly 05 KG


battery set As per

requirement 13 Mercury in Glass Thermometer (0-100ºC) having suitable

scale representing 1ºC temperature rise and Gravity correcting scale

02 Nos.


02 Set

15 Cell Testing Digital Voltmeter 3-1/2 digit LCD screen [(-)3-0-(+)3] DC Volt)](0.05 V resolution)As per IS:1248(Latest edition)

02 Nos.

16 Wooden stand 01 Set 17 Insulated spanner set 02 Nos. 18 Plastic Syringe-10 oz 02 Set 19 Acid resistance funnel-Dia=6 inch (150 mm) 02 Set 20 Rubber Syphone- Dia=0.5 inch (12.7mm), L=2 meter long 02 Set 21 Rubber Glows 04 Pair 22 Rubber Apron 04 Nos. 23 Acid resisting plastic jugs (2 Litre capacity) 02 Nos. 24 Rubber boots Knee height 04 Set 25 Spare cells for above set with lid 04 Nos. 26 Instruction manual 02 Set 27 Operation and Maintenance manual 02 Set28 Battery bank characteristic curves 02 Set


25


ANNEXURE-A6 LIST OF ADDITIONAL ACCESSORIES (FOR EACH STATION-SET)

SR. NO. ACCESSORY QTY 1 Inter Cell Connector 10 % of Set* 2 Inter Bank Connector 01 No.3 Inter Raw Connector 02 Nos.4 Fasteners 10 % of Set*5 Micro Porous Vent Plugs 10 % of Set*6 End Cell Takeoffs 01 Nos. 7 Lead Washer 10 % of Set*8 Cell Support Insulators 10 % of Set*9 White Petroleum Jelly 02 KG

10 Cell Number Plate(No Sticker) with fixing pins 110 Nos. 11 Level Indicating Floats 10 % of Set* 12 Cell Electrolyte(Specific Gravity 1.200)-to commission

battery set 10 % of Set*

• Set means total quantity required for complete battery set i.e. 110/186/63 cells.

26


ANNEXURE-A7

EXISTING ARRANGEMENT OF BATTERY SETS

27


B

Note: - All above dimensions are in mm.

4230

Entry+Ve -Ve

11156

A - Existing 220 V Lead Acid Tubular Battery Set No. 2 in Single Tier Double Raw Wooden Stand Arrangement which is required to replace. B - Existing 220 V Lead Acid Tubular Battery Set No. 1 in Single Tier Double Raw Wooden Stand Arrangement. C - Existing 48 V Lead Acid Tubular Battery Set in Single Tier Double Raw Wooden Stand Arrangement.

AA

B

+ Ve - Ve

C

+ Ve -Ve

Existing Battery Set Arrangement in Ukai Main Hydro

7055

880

880

6375 6375

645 645

9570

28


29


30


31


32


LAY OUT SKETCH OF EXISTING 220V 1000AH BATTERY SET AT SIKKA UNIT NO. 01 ( SET HAS 04 RAW ARRANGEMENT )

830 cm

350 cm

50 cm

60 cm

Battery Cell

Battery Stand

LAY OUT SKETCH OF EXISTING 220V 1000AH BATTERY SET AT SIKKA UNIT NO. 01 ( SET HAS 04 RAW ARRANGEMENT

33


SCHEDULE OF GURANTEED TECHNICAL PARTICULAR (TO BE FILLED UP ALONG WITH OFFER OF BATTERY SET)

SR NO

BATTERY SPECIFICATION UKAI TPS

UKAI HPS

UKAI MINI

HYDRO

DHUVARAN CCPP

SIKKA KLTPS

SCHEDULE : SR.NO. 1 2 3 4 5 6 7 81 Name of Manufacturer 2 Type and Designation 3 Details of electrolyte-

(i) Type/Grade (ii) Quantity per cell (iii) 10% extra quantity (iv)Grand total quantity

in Litre.

4 Voltage Rating of each cell- When battery is: (a) Floating (b) Nominal (c) Fully charged

5 Voltage of each cell on complete discharge at 5 hour rate.

6 Open Circuit Voltage of battery bank of full charge

7 Minimum Voltage per cell at which it can be operated safely at 5 hour rate of discharge

8 Ampere-Hour capacity 9 Internal Resistance per

cell

10 (a)Normal charging rate

(b)Starting charging rate (c)Finishing charging rate (d) Trickle charging

rate (e) Discharge rate on 3

minutes basis in ampere at end voltage 1.85 V/Cell for lead acid Battery cell

11 Guaranteed efficiency-

34


(a)Ampere-Hour Efficiency

(b) Watt-Hour Efficiency12 Discharge capacity in

ampere hour at 27° C- (a) 10 hour rate (b) 9 hour rate (c) 8 hour rate (d) 7 hour rate (e) 6 hour rate (f) 5 hour rate (g) 4 hour rate (h) 3 hour rate (i) 2 hour rate (j) 1 hour rate (k) 45 minute rate (l) 30 minute rate (m) 15 minute rate (n) 5 minute rate

13 Fully charged specified gravity of the electrolyte

14 Fully discharged specified gravity of the electrolyte

15 Slow charging rate 16 Quick charging rate 17 Float charging voltage

per cell

18 Gasification voltage per cell

19 Recommended Float charging-

(a) Voltage (b) Current

20 Recommended Boost charging-

(a) Voltage (b) Current

21 Recommended Trickle Charging current rate-maximum/minimum

22 Short Circuit Current for Dead Short across terminals

23 Short Circuit Current for Dead Short across terminals when-

35


(a)Float Charge at 2.20 volt per cell

(b)Boot Charge at 2.75 volt per cell

24 Cell Container: (a)Dimension(Width x

Depth x Height) (b) Thickness (c)Material of container

25 Minimum weight of each cell: With/Without electrolyte

26 Type, Material, Nos. and cross sectional area in sq.mm of- (i) Positive plate (ii) Negative plate

27 Material, Thickness and Type of Separator

28 Size, Material and Resistance of inter-cell connector and method of connection between cells

29 Material of inter-row, inter-tier connector

30 Material of bolts/nuts/ washers for inter-cell/ cable connectors

31 Minimum Lead Coating 32 Amount of Hydrogen

evolution during-per cell (a)Equalizing charge (b)Boost charge (c)Float charge

33 Distance between cell centers

34 Material of Lid 35 Material of 36 Clearance between-

(a)Bottom of positive plates and container

(b)Bottom of negative plates and container

36


(c)Top of positive plates and container

(d)Top of positive plates and container

37 Level of acid above plates

38 Average life of battery offered

39 Wooden Stand : (i)Size of stand (ii) Size of support angle (iii)Nos. of rack per Battery set (iv)Dimension (H x W x

L) (v) Min. weight (Kg.)

40 Permissible maximum temperature of electrolyte- (a)During initial charging (b)During normal

operation

41 Performance Curve-State Design values- (i) % AH after 5 Year

and 10 year (ii)Discharge rate (end

voltage) at 5 hour and 10 hour

(iii)Charging curve cell voltage at 60 hour and 100 hour

(iv)Discharge Amp v/s time curve-Amp for 1 hour and 10 hour

INDICATE QUANTITY FOR ALL THE FOLLOWING ACCESSORIES PER SET- 1 Lead plated Copper

connector (Size and Quantity)- (a) Inter cell (b) Inter row (c) Inter tier (d) Inter rack

2 Details of Stand

37


insulators- (a) Material (b) Size (c) Quantity

3 Hydrometer with stand 4 Cell Tester 5 Thermometer with stand 6 Details of Electrolyte-

(a) Type (b) Litres per cell (c) First filling + 10% extra

in Litre (d) No of carboys (35 L)

7 Acid Filler (Rubber Syringe)

8 Acid Resistance Plastic Jug

9 Acid Resistance Funnels 10 Cell Number plate 11 Lead plated MS / SS

Nut-Bolts, washers (a) Size (b) Quantity (Nos. + extra = Total)

12 Ceramic Vent Plug 13 Insulated Spanner Set

(Size and Nos.)

14 Level Indicator 15 Petroleum Jelly 16 Rubber Boot 17 Rubber Gloves 18 Rubber apron 19 Log book

NOTE: Over and above GTP, the Bidder shall also fill up and submit the checklist for each of the offered battery set, given separately, with these specifications.

Documents

GUJARAT STATE ELECTRICITY CORPORATION LIMITED · (a) Battery of 220 V, 1300 AH rating shall consist of 110 numbers of series connected HDP lead acid cells of 2.0 Volts, having 1300