Material SPECIFICATION No. RDSO/PE/SPEC/TL/0040-2003(Rev-0)

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

RESEARCH, DESIGN AND STANDARD ORGANISATION MANAK NAGAR LUCKNOW-226011

SPECIFICATION FOR LOW MAINTENANCE LEAD ACID 40 AH AND 200 AH

CELLS FOR TRACTION DISTRIBUTION SYSTEM. 0.0 FOREWORD 0.1 In Traction Distribution System, 40Ah and 200Ah capacity cell is used for installations in the control rooms at unattended switching stations and traction sub stations. 0.2.1 The batteries for traction sub-stations and switching stations shall be of single cell construction and 55 cells constitute one set. 0.2.2 All types of traction sub-stations and switching stations shall be provided with single set of cell. 0.2.3 The rated capacity of cell shall be 2V, 40Ah for switching stations & 2 V, 200 Ah for traction sub-stations at 27 degree centigrade. 0.3 In the preparation of this specification assistance has been drawn from the following publications. (1) IS: 1146-1981 (2) IS: 6848-1979 (latest) (3) IS: 266-1993 (4) IS: 1069-1993 (5) IS: 6071-1986 (6) IS: 3116-1965 (7) IS: 8320-2000 (8) IS: 4905-1998 (9) IS: 1651-91(latest) (10) IS: 1652-91(latest) (11) RDSO Spec. No. ELPS/SPEC/TL/09 (Dec , 1996) with Amendment No.2 (12) RDSO Spec. No. ETI / PSI/21(6/81) with A& C Slip No. 1 (13) RDSO Spec. No. ETI / PSI/25(6/81) with A& C Slip No. 1

1. SCOPE 1.1 This specification covers the design, manufacture, method of test and other requirements of low maintenance stationery lead acid batteries for installation in the control room at un - attended 132/25kV or 220/25kV traction sub stations (TTS) and at un-attended sectioning and paralleling posts (SPs) and sub-sectioning and paralleling posts (SSPs). The battery shall be of low maintenance design such that it requires very less topping up in the actual service. Frequency of topping up shall be not earlier than 9 months. However, attempt should be made to increase this period to 12 months. 1.2 The batteries shall be complete with all parts and accessories, which are necessary for their efficient operation including the supporting stands. All such parts and accessories shall be deemed to be with in the scope of this specification. 1.3 The batteries shall be delivered in the dry uncharged condition ready for filling electrolyte and use at site. Sufficient quantity of electrolyte required for first filling with 10% extra shall be supplied separately in non-returnable containers. 2.0 TERMINOLOGY 2.1 TYPE TESTS:-. These are intended to prove the general quality and design of a

given type of battery. 2.2 ACCEPTANCE TESTS:- Tests carried out on samples selected from a lot for the purpose of verifying the acceptability of the lot. 2.2.1 LOT:- All batteries of the same type, design and rating manufactured by the same factory during the same period using the same process and materials, offered for inspection at a time, shall constitute a lot. 2.3 ELECTROLYTE:- Aqueous solution of sulphuric acid for ionic conduction and Electro-chemical reaction during passage of current through a cell. 2.4 TERMINAL POST (lug): - A post (lug) of a cell or battery to which an internal electrical circuit is connected. Positive and negative terminal post shall be clearly and unmistakably identifiable. The positive terminal shall be marked with red colour in addition to '+' marking. 2.5 FLOAT:- A device for indicating the level of electrolyte in the cell container. 2.6 FLOAT GUIDE:- A removable bush of anti-splash and sealed type to facilitate easy vertical movement of float stem. 2.7 VENT-CUM-FILLING PLUG:-A removable plug for fitting into the vent hole. 3.0 MATERIAL AND CONSTRUCTION

3.1 The cells shall be similar in type and shape. Lifting handle either moulded or rope type shall be provided with suitable strength. 3.2 The maximum overall dimensions of the cells up to terminal shall not exceed the

values given in the table 1 of clause 7.1 of IS:1651-1991.The dimensions do not include the projection of float.

3.3 The weight of cells with the electrolyte shall not exceed to the value 31 Kg and 10 Kg for 200Ah and 40 Ah cell respectively. 3.3.1 The cell shall be so designed that the initial charging of the cell shall be completed within 75 hours as per the charging method to be prescribed by the manufacturers to the type testing authorit y as well as in the Maintenance Manual. Subsequent charging for conducting various tests shall be restricted to 15 hours. 3.3.2 All the positive or negative plates shall be insulated at edges to avoid side shorting. 3.4 CONTAINER AND LID 3.4.1 HARD RUBBER CONTAINER/LIDS: The cells shall be supplied in containers, which shall conform to IS:1146-1981 with latest amendment. The minimum height from the ball, as defined in the IS:1146-1981, when dropped which causes the fracture, shall not be less than 400mm (min. single time drop) for each side. However for 40 Ah cell the height which causes the fracture shall not be less than 200 mm. The design will provide for adequate safety margins for achieving the required strength. Cell lids shall be either drop-on type together with suitable gasket or of the deep sealing type suitable for use of bituminous sealing compound, with close-fitting terminal post outlets and with vent- holes suitable for accommodating the float guide and filling plug -cum-vent plugs. 3.4.2 PLASTIC CONTAINER/CELL LIDS: 3.4.2.1 The individual cells may be supplied with plastic containers / lids. The container/lid shall have adequate strength with design margins to meet the actual field conditions as prevalent over Indian Railways for which battery manufacturers shall wholly be responsible notwithstanding the approval given by the RDSO . Adequate measures shall also be taken by Manufacturers to avoid bulging of cells along shorter / longer sides of the cells. Despite of the above design measures having been taken by the manufacturers, if failures of cells on account of the container/lid material/inadequate design are reported from the field, the manufacturers shall replace these cells with new

cells having improved design with plastic/hard rubber container/lid as approved by the RDSO free of cost within the warranty period. If design of the container/lid is with strengthening member/rib, it may be provided inside or out side of the container/lid. In this case wall thickness refers to the base(web) thickness only and does not include thickness of rib or strengthening members. However the overall outer dimension shall not exceed the values specified as per clause 3.2.The design of container and lid shall generally conform to the following specifications. (1) Material Specification for PP-CP (Polypropylene Co polymer) Container/lid Fire retardant (V2 Grade) (2) Wall thickness of container 3.5 mm to 6.5 mm The outer wall thickness shall be measured on all sides of the container i.e longer side, shorter side, and base. However, the minimum wall thickness of container/lids shall not be less than3.0 mm if design of the container/lid is with strengthening member/rib. (3) Tests: These PP-CP containers shall be subjected to the tests as per Clause 7 of the

IS:1146-81 and the following tests shall be conducted during prototype testing 1. Verification of constructional requirements 2. Verification of marking and packing 3. High Voltage test 4. Drop Ball test 5. Plastic Yield test 6. Acid resistance test. In addition, a test for checking the proper sealing of the container with the lid as per 5.13 shall be conducted during prototype test as well as acceptance test, if the lifting handle is provided on the lid. 3.4.2.2 In order to have standardization of float guides, it should conform to drawing no. RDSO/PE/SK/TL/0031-02 (Rev 0 ). Float guides of dimensions different than above drawing may be accepted in special circumstances to be explained by the vendor. 3.4.3 MICRO POROUS VENT PLUG: Each cell shall be provided with adequate means, both for venting and for servicing of the electrolyte. The vent -cum-filling plug shall generally conform to RDSO drawing No. 4020/A Alt. 3 with the dome /filter made of ceramic or any other suitable fire retardant material. For smaller battery i.e. 40Ah size of vent plug can be smaller. The vent-cum-filling plug shall allow free escape of gases evolved during service and shall not permit electrolyte to come out on the surface of the

lid. On removal of vent-cum -filling plug, drawing of the electrolyte sample, servicing and checking of electrolyte shall be possible. 3.4.3.1 The material used for micro -porous vent plug shall have uniform porosity. It shall also be free from abnormalities such as crack, breakage, foreign matter, dent and shall conform to the following. The following tests shall be applicable on Micro -porous dome of the vent plug only and dome shall be taken out for this purpose. a) Porosity : 35 ± 5% Porosity of micro-porous filter shall be calculated as given below:- Weigh the sample in air (W1). Keep the sample in boiling water with few drops of wetting agent (Teepol ) for 30 mts. Weigh the sample in water (W2). Next weigh the wet sample outside water (W3). Calculate porosity as under: a) Porosity % = (W3-W2)-(W1-W2) ------------------------------X 100 (W3-W2) b) Breaking Strength: Shall not be brittle. To test this, a steel ball of 200 gm shall be dropped two times from the height of 400mm on the top and side of micro-porous dome. c) Acid resistance: Dry and weigh the (micro-porous body) dome (W1), Keep the dome in sulphuric acid of Sp. Gr. 1.3 at 40 Degree centigrade for 100 hours. Remove it from acid, wash free of acid, dry and weigh (W2) . Calculate the percentage loss as follows W1- W2 -----------X100 W1 The loss of weight shall not be more than 0.5% d) Permeability : The full charge cell shall be fitted with vent plug and charged at 2.5 times of C10 rate for 4 hours. All sealed Float guides shall be in position properly except the one where manometer with water is fitted. The cell shall not develop positive pressure more than 2 mm of water column inside the cell. e) Dimension : Shall generally conform to RDSO's drg. No. SKEL-4020/A Alt. 3 or as approved by RDSO f) Plastic Component : Plastic component to which the micro -porous top is bonded shall be free from crack, flash, pin hole, air bubble, uneven shrinkage foreign particles etc. and shall conform to the following (Ref. Drg. SKEL-4020 Alt. 3) : ABS Fire retardant or superior quality

Acid Resistance : No perceptible change Heat : NO deformation at 70 deg. C 3.4.3.2 DIA AND PITCH THREAD:- The micro-porous vent cum- filling plug and

sealed float guide dia shall be 27 mm and pitch of thread shall be 3 mm as per Drawing No. SKEL-4020/A Alt. 3 (sheet no.2 )

3.4.3.3 Each cell shall have one micro porous vent -cum -sealed float guide type for 40Ah and having dome /filter made of ceramic or any other suitable fire retardant material and meeting the requirements specified in clause 3.4.3 3.4.3.4 For 200 Ah each cell shall have one float guide sealed type and one vent-cum-filling plug as mentioned above. 3.4.3.5 Each cells (i.e. 40Ah/200Ah) shall be provided with two terminal lugs made of lead alloys, one negative and one positive according to fig. 1 of IS: 6848 except the thickness of lug which shall be 5 mm minimum for 40Ah and 12 mm for 200Ah . The positive terminal lugs shall have rounded edges and the negative terminal lugs shall have pointed edges, so to be easily distinguishable ( fig. 1 of IS:6848-79) 3.5 INTER -CELL AND END -CELL CONNECTORS: 3.5.1 Inter -cell connectors for one set consisting of 55 cells of 40Ah and 200 Ah shall be provided. The quantity to be supplied is given below. i) Inter cell connector = 52 numbers ii) Inter row connector = 2 numbers (Cell No. 14-15 and 42-43) iii) Take off terminal = 2 numbers (End cells) iv) Inter tier connector = 2 numbers (Cell No. 28 & 29) v) Fasteners = 220 numbers The fasteners M6X30for 40 Ah and M8x30 for 200 Ah shall be used. 3.5.1.1 Connector: (i) The cable connectors should have lead coating to withstand any corrosive

attack. The thickness of the lead coating of lugs shall not be less than 25 microns. The lead coating thickness shall be measured in accordance with Appendix 'F' of IS: 6848-79 with Amendment No 1,2 & 3.

(ii) The cables shall be of elastomeric type with composition class -6 of Table no.

1 of RDSO approved make conforming to RDSO Specification NO. Spec./E-14/01 Part I (Rev. II)-1993.

(iii) The design shall be such that the voltage drop across the cell cable connector in the battery bank, shall not be more than 15mV per connector at C10 rate. However, efforts shall be made to keep this voltage drop as minimum as possible. Cable connector shall be of size 18 Sq. mm for 40Ah and 40sq. mm for 200 Ah. respectively.

(iv) In the design, adequacy of contact pressure leading to low contact resistance

shall be considered and accordingly suitable fastening arrangements shall be suggested /provided by the manufacturers. The details of recommended testing procedures and its frequency to ensure low voltage drop etc. shall be laid down by the manufacturers with consultation of RDSO.

3.5.2 Nut and Bolts for connecting the cells shall be made of copper, brass, stainless steel or any other suitable alloy and effectively lead coated to prevent corrosion. However acid resistance stainless steel bolts and nuts need not be provided with lead coating. 3.6 ELECTROLYTE: It shall be prepared from battery grade sulphuric acid conforming to IS: 266-1993 with latest amendment. 3.6.1 A suitable electrolyte level indicator indicating lower and upper limits shall be fitted to facilitate checking of electrolyte level in opaque containers. The materials used shall be acid proof and shall not deteriorate during service. 3.6.2 The specific gravity of electrolyte when the cells are in fully charged condition at 27 degree Centigrade shall be between 1.210 to 1.220. The specific gravity shall be corrected to 27 degree Centigrade using the formula given under cl. 3.2.2 of IS:8320 1982. 3.6.3 WATER: - The water used for topping up and preparing electrolyte shall conform to IS:1069-1993 3.7 SEPARATOR:- Separator shall be Micro porous rubber, PVC or any other material conforming to IS:6071-1986. The volume porosity shall be not less then 35% 3.8 SEALING COMPOUND: Sealing compound, if bitumen based shall conform to IS:3116-1965 with latest amendment. 3.9 BATTERY STAND: Supply of battery stand is optional and should be supplied if asked by the purchaser with each battery set. The battery stand shall be of double row double tier construction made of 4.0 mm thick M.S to accommodate the battery. (3 mm thick MS can be used for 40 AH cells) The battery stand shall be painted all over with three coats of acid resisting varnish conforming to IS:342-1976. The battery stand shall be provided with cell number plates and shall be manufactured as per drawings approved by the purchaser. 3.9.1 Electrical insulating grade and acid resistsant PVC sheet, not less than 3mm thick, for supporting the cells on the battery stand and necessary support insulators shall be supplied to suit the battery stand. 4.0 SERVICE CONDITION

4.1 The batteries are intended for use in moist tropical climate in India where the maximum ambient temperature may reach 45 deg. C in shade, the daily average maximum ambient reaching 35 deg. C, with a relative humidity reaching up to 100% 4.2 40Ah batteries are required as a reliable power source for operation of the interrupter and the various control/indication circuits at the unattended 25KV switching stations, located along side Railway track for controlling power supply to the traction overhead equipment. 200Ah batteries are required as a reliable power source for operation of switchgear and various control /indication circuits at the unattended traction sub-station. 4.3 The batteries will be normally kept on trickle charge by suitable battery charger. During AC supply failure or battery charger failure the battery will be called upon to delivery the full load for operation of the interrupters and the various control/indication circuits. 5.0 RATING: 5.1 RATED CAPACITY: The rating assigned to the battery shall be capacity (C10) in ampere hour (after correction at 27 degree centigrade temperature) when the cell/ battery is discharged at 10 hr rate to the end voltage of 1.85V per cell. 5.2 DECLARED CAPACITY: Since the declared C10 capacity of the battery is generally higher then rated C10 capacity, the manufacturer will advice the declared C10 capacity of the battery. 5.3 OBTAINED CAPACITY: Obtained capacity is the capacity obtained during the discharge of cell upto 1.85 V at 10 hours rate of the rated capacity of the battery. The variation between declared capacity and obtained capacity shall not be more than ±3 percent. 5.4 TESTS AND PERFORMANCE: 5.4.1 Classification of tests 5.4.2 Type tests- The following shall constitute the type tests. All these tests shall be started after 3 cycles of charge/discharge at 10 hour rate. All these tests shall be conducted at 27±3 degree Centigrade unless and otherwise specifically mentioned. a. Capacity at 10 hrs. rate (Obtained Capacity) according to cl. 5.6 of this spec. b. Watt hour and Ampere hour efficency tests according to Clause 5.7 of this spec. Watt hour efficency shall not be less than 80 percent and Ampere hour efficency shall not be less than 95 percent. While conducting this test a minimum rest of 12 to 24 hours shall be given between each charge/discharge.

c. Retention of charge according to clause 5.8 of this spec. Loss of capacity shall not be more than 3 percent of the initial capacity (OTC) after 14 days. For this battery can be stored at room temp. but not less than 22 degree centigrade. Charge/Discharge for this test shall be conducted at 27±3degree centigrade. d. Life test shall be conducted according to clause 5.9 of this specification. After completion of life cycle test the cell shall be cut opened and examined to arrive at the reason for reduction in capacity. e. Storage test according to clause 5.10 of this spec. f. Air pressure test according to clause 5.14 of this spec. g. Checking of dimensions, mass, marking and workmanship according to clause 3 and 6.0 of this spec. h. Material and component specification verification test according to clause 7.0 of this spec. i. Loss of water as per clause 5.11 of this spec. j. Test of Micro- porous vent plug as per Clause 3.4.3 of this spec. k. Equilibrium float current test as per Clause 5.12 of this spec. l. Sealing of container with lid as per clause 5.13 5.5.0 SEQUENCE OF TYPE TESTS: The sequence of type tests and the number of samples required shall be in accordance with Appendix "C". 5.5.1 If any of the samples fails in the relevant type tests, the testing authority may call for fresh samples not exceeding twice the original number of cells tested in that particular test and subject them again to test(s) in which failure occurred. If there is any failure in the retest(s), the type shall be considered as not having passed the requirements of this standard. 5.5.2 DURATION OF TYPE TEST: Type tests as per clause 5.4.2 shall be completed within six months (Maximum) from the date of starting the type test. Except storage test which shall be completed in two years from the date of starting the test. 5.5.3 INSPECTING AUTHORITY : The type test as per clause 5.4.2 of cells shall be conducted by the representative of RDSO/Lucknow, India at the works of manufacturers at their cost.

5.5.4 ACCEPTANCE TESTS: 5.5.4.1 The following tests shall be conducted as acceptance tests:- a. Capacity test at 10hrs. rate according to clause 5.6 of this spec. The capacity obtained shall not have variation of more than ± 5 percent of the capacity obtained (as approved by RDSO on the capacity obtained) during prototype testing. The weight of dry cell shall not vary more than ± 5 percent of the weight obtained during prototype testing. b. Checking of dimensions, mass, markings and workmanship as per clause 3 & 6. c. Checking of container strength on assembled cell shall be done by dropping a ball from a height of 400 mm for 200Ah cell and 200 mm for 40Ah cell as per clause 7.8 of IS:1146-1981. The container should not crack. For verification of crack, air pressure test shall be done. This test shall be conducted on five No. of assembled cell for each lot. 5.5.5 SAMPLING SCHEME AND CRITERIA FOR ACCEPTANCE: A recommended sampling scheme and criteria for the acceptance of the lot for various lot sizes is given in Appendix 'D'. 5.6 TEST FOR CAPACITY AT 10HRS. RATE 5.6.1 After standing on open circuit condition for not less than 12hrs. and not more than 24 hrs. form the completion of a full charge, the battery shall be discharged through a suitable resistance at a constant current I= 0.1X C10 amperes, and discharge shall be stopped when the closed circuit voltage across the battery terminals falls to 1.85 volts per cell. 5.6.2 At this rate of discharge, hourly voltage readings may be taken until the battery voltage approach 1.90 volts per cell after which the readings shall be taken every 15 minutes until the voltage falls to 1.85v/cell. 5.6.3 On the first discharge the battery or cell shall give ±3 percent of declared capacity. 5.6.4 The battery shall be charged at normal charging rate immediately after discharge. The charging of batteries may be carried out for test purposes using constant potential charging method or constant current charging method as recommended by the manufacturer. 5.6.5 The capacity in Ampere hour shall be obtained by multiplying the discharge current by the total time of discharge in hours and the product so obtained shall be corrected to a temperature of 27 degree cerntigrade by the following formula:-

The capacity at 27 deg. C. = CT -------------- 1+ K(t-27) Where CT is the observed capacity at t degree Centigrade. K is the variation factor 0.0043. t is the average room temperature in degree Centigrade. 5.6.6 The capacity at 10 hrs. rate shall within ± 3 percent of declared capacity . 5.6.7 After 10 hrs discharge the cells/battery should be charged at normal charging period within 15 hrs. 5.7 TEST FOR AMPERE HOUR & WATT HOUR EFFICENCY 5.7.1 The following method shall be used for determining the maximum ampere hour and watt-hour efficiencies. 5.7.2 Ampere hour efficiency: A fully charged battery shall be discharged at I=0.1xC10 amperes to a end voltage of 1.85 volts/cell, care full measurements being made of exact number of ampere hours delivered. On the recharge the same number of ampere- hours are put back at the same current. A second discharge shall then be made to the same cut off voltage as before. The efficiency of the battery is then calculated as the ratio of the ampere- hour delivered during the second discharge to the ampere hour put on the charge. 5.7.3 Watt hour efficiency. The watt hour efficiency shall be calculated by multiplying the ampere - hour efficiency by the ratio of average discharge and recharge voltages. The values of discharge and recharge voltages shall be calculated from the log sheets for ampere hour efficiency. 5.8 TEST FOR RETENTION OF CHARGE The object of this test is to determine the loss of capacity of a battery unit on open circuit during a specified period. 5.8.1 The battery unit shall be fully charged at the normal charging rate specified by the manufacturer and it shall then be subjected to two consecutive capacity test discharges in accordance with clause 5.6, the value of the initial capacity, C being calculated as the mean of the two results thus obtained. 5.8.2 After a complete recharge and after cleaning the surface, the battery unit shall be left on open circuit for a period of 14 days without disturbance at ambient temperature.

5.8.3 After14 days of storage of the battery unit shall be discharged in accordance with clause 5.6. The value of the capacity measured after storage shall be denoted by C1. 5.8.4 After the discharge the battery unit shall be fully charged at the normal charging rate recommended by the manufacturer. 5.8.5 The loss of capacity's expressed as a percentage, shall be calculated from the formulae. S= C- C1 ----------- X100 C 5.8.6 Requirement: The loss of capacity calculated as in 5.8.5 shall not be more than 3 percent over 14 days storage period. 5.9 LIFE TEST It should be conducted as per clause 12.8(endurance test ) of IS1651-1991 applicable to normal cells. 5.9.1 REQUIREMENT: The cell shall give not less than 9 hour of discharge at 10 hour rate, till end voltage of 1.85 volt. 5.10 STORAGE TESTS 5.10.1 The cell/battery unit shall be capable of being stored unfilled for a period of 24 months from the date of sealing by inspecting authority. After storage for the specified period, the battery unit shall be tested as per clause 5.6 5.10.2 The capacity after 24 months, when tested as above shall be not less than ± 3 of the obtained capacity. 5.11 LOSS OF WATER TEST: 5.11.1 After fully charging the cell it should be cleaned and dried. It should be weighed immediately but not exceeding one hour after drying with an accuracy of 0.05 percent or maximum least count of 50gm for the balance used. Then all vent cum-filling plugs should be closed tightly and connected to constant voltage charger keeping the voltage 2.4 ±0.05 volts per cell for 21 days in water bath at the temperature of 50± 2 degree centigrade. Thereafter cell is removed from circuit and dried. After this it is weighed accurately. 5.11.2 The water loss shall not exceed 0.8gm/Ah/cell of the obtained capacity. 5.12 EQUILIBRIUM FLOAT CURRENT TEST;

5.12.1 This test shall be conducted during the initial three days (72 hours) of water loss test. The cell under test shall be kept in water bath at 50± 2 degree Centigrade. Charging voltage shall be 2.4 ±0.05 V per cell. The float current shall be measured and recorded. It shall not be more than 3mA/AH of the obtained test capacity. 5.13 TEST FOR SEALING OF CONTAINER WITH THE LEAD The test shall be conducted after filling the cell with the electrolyte up-to-the maximum permissible level. The filled battery shall be kept in water bath of temp. 50 ± deg. C for 2 hours. A jig shall hold the battery container alongwith a dead weight equal to the weight of fully topped up battery. The battery shall be lifted by the lifting handle provided on the battery lid. The same shall hold for 5 minutes. The cell lid shall not show any visible sign of movement at the sealing joint. 5.14 TEST FOR AIR PRESSURE The sealing of each cell of the battery shall be checked by compressed air at a pressure equal to 700 mm of water. The volume of tubes and auxiliary parts in connection with the cell under pressure shall not exceed 0.5 liter. Air pressure in the cell shall be noted 15 seconds after the supply has been disconnected and it shall not fall below 670 mm of water. 5.15 TEST EQUIPMENTS: 5.15.1 The voltmeters, Ammeters, Thermometer and Hydrometer etc. required the tests specified in this standard shall meet the requirements given in Clause 10.2 of IS: 8320. Where digital ammeter /voltmeter are used, the meter shall be capable of displaying up to two decimal in the range 0 to 99 volts and one decimal in 100 and above volts range. Use of digital ammeter/voltmeter is preferable for testing capable of displaying at least upto one decimal of the current to be measured data recorders shall be used for C10, Ah and Wh efficiency, ROC I & II and life cycle testing with continuous logging facility of voltage, current , AH input/output with reference to time. Manual recording is not permitted. 5.16 TEMPRATURE FOR TEST:- Unless otherwise specified the temperature for test shall be between 20 degree and 32 degree centigrade, unless it is unavoidable 6.0 MARKING & WORKMANSHIP 6.1 For Hard Rubber Container:-

Marking -Both the shorter or longer sides of such container shall have the following details embossed on the container:- a) Manufacturer's name or trade mark and place of manufacturing, b) Rating at 10hrs. discharge rate, and c) Specific gravity of the electrolyte in the fully charged condition at 27 deg. C. Note: STICKER not permitted on cells. 6.1.1 For plastic container: Marking - On the top lid or container wall such details embossed are required: a) Manufacturer's name or trade mark of manufacturing Both the shorter or longer sides of such container shall have the following detail stencil on the container, a) Manufacturer's name or trade mark b) Rating at 10 hrs. discharge rate and c) Specific gravity of the electrolyte in the fully charged condition at 27±2 deg. C d) Place of manufacturing Note: STICKER not permitted on cells 6.1.2 The year and month of manufacture shall be punched on the terminal lug base. 6.1.3 Manufacture name or trademark and rating of battery will be stenciled or embossed on the connector.or on lid in ppcp container if marking are not imbossed in container Workmanship: The container shall be from any cracking or chipping or distortion and any sign of leakage or spillage 6.1.4 A yellow band of 25mm width shall be provided on both sides along the width of the cell for easy identification of low maintenance batteries. 6.2 Cells should be suitably packed to avoid damage due to rough handling in transit 7.MATERIAL AND COMPONENT SPECIFICATION VERIFICATION TEST: 7.1 The battery shall be examined in the dismantled condition to see that the manufacturing is to the approved outline and assembly drawing and the various components are conforming to the specification as detailed above. The samples of sealing compound, separator, container and electrolyte shall be taken at random from the manufacturing line and tested to see that they meet requirements of the relevant specifications.

8. MAINTENANCE TOOLS AND INSTRUCTIONS: A wall mounting type " Tool Board" of suitable material and protected against acid fumes shall be supplied along with each battery bank. The tool Board shall comprise:- i. One Syringe for adding or taking out electrolyte from the cells. ii. One syringe type hydrometer of requisite range for measuring the specific gravity of electrolyte in the cells. This shall be provided with a graduated scale, one division of which representing at the most 0.005 unit of specific gravity with accuracy of calibration not less than 0.005 units of specific gravity. iii. One cell-testing-voltmeter 0-3 volts of accuracy class 0.5 in accordance with IS: 1248-1968. The resistance of the Voltmeter shall be 1000 Ohms per Volt. iv. One thermometer with an appropriate scale for measuring temperature of electrolyte. One division of the graduated scale of the thermometer shall represent at the most 1deg. C, the accuracy of calibration being not less than 0.5 deg. C. 9 DRAWING 9.1 The manufacturer shall supply two sets of drawing in A4 size listed a below for approval while offering the cell for type testing. (a) Detail drawing with dimensions of front, top and side view of the cell. (b) Detail drawing of the container showing different sections with dimensions. (c) Part drawings with sectional details of - (1) Terminal Post (positive and negative) (2) Container lid (3) Pole + and - (4) Plates (+ve and -ve groups assembly) (5) Separator (6) Sealed float guide (7) Micro porous vent plug (8) Inter cell / unit and end cell connectors (e) General arrangements of drgs. of 56 cells set indicating connections from cell to cell. (f) Any other drgs. Considered relevant 10.0 For the purpose of the cells supplied against this approval, approval means the approval of general design features. Not with standing the approval, manufacture is

wholly and completely responsible for performance, life and reliability of battery during service. 10.1 Before offering the battery for prototype testing, all relevant drawings as considered by the RDSO, shall have the approval of competent authority. The manufacturer shall produce only drawings approved by competent authority during the prototype inspection and shall not undertake any modification until such time battery under prototype testing is completed and the observations of RDSO are recorded. 10.1.1 After the prototype approval by RDSO of a batteries design etc, no design change shall be undertaken by manufacturer on prototype cells/ batteries without prior approval of RDSO, failing which the prototype approval may be with drawn by RDSO at any time. 10.2 Not withstanding the above recommendations , manufacturer is wholly and completely responsible for pe rformance, life and reliability of battery during service, It is also subject to satisfactory compliance to the various requirements like satisfactory online performance, quality assurance plan as approved by RDSO, successful completion of contracts/ Purchase orders placed by Railway Board/Production Units/Railways etc. 10.3 All manufacturer are advised to ensure that the batteries mentioned in these recommendations, have valid type approval certificate failing which no further extension of approval may be granted by this office. The entire responsibility of the offering the batteries timely in advance to RDSO for type testing lies wholly on the manufacturer which may be noted. RDSO in no case shall be held responsible for reminding the firm in this connection. Application for revalidation of type approval certificate shall be made at least six months in advance prior to expiry of validity of earlier approval granted. 10.4 If considered necessary, RDSO may undertake re-testing of some or al prototype tests as per specifications at any time to ensure proper effective quality control being exercised by the manufacturer at different stages of manufacturing. 10.5 RDSO may, also, undertake some special tests associating manufacturers to validate the design changes for which all the necessary testing equipment / instruments etc. shall be arranged by the manufacturer free of cost. 10.6 DESIGN DOCUMENTS AND INSTRUCTIONS MANUAL: Following documents in the spiral bound form will be submitted to the RDSO. a) Two set of drgs. As per clause 9.0 of this specification before offering for type test for approval and one set for records (bound form) after completion of type tests. b) (i) In house test results as per appendix 'A' and 'B' shall be sent to RDSO before offering for type test. (ii) Type tests results obtained by testing authority.

c) Instructions manual -Two copy of instruction manual with each lot to consignee and one copy to RDSO 11.0 Alternative superior designs can be considered provided necessary technical justifications with benefits is furnished for scrutiny. 12 AFTER SALES SERVICE 12.1 The successful tenderer shall make necessary arrangements for closely monitoring the performance of equipments through periodical (preferably once in two months during the warranty period) visits to the location where they have been erected / installed for observations and interaction with the operating and maintenance personnel of the Indian Railways. Arrangements shall also be made by the successful tenderer for emergency / standby spare parts being kept readily available to meet exigencies warranting replacement so as to keep the equipment in service with least down time. 12.2 The successful tenderer shall respond promptly and in a workman like manner to any call given by Indian Railways for any assistance by way of attending to failures. Investigation into the causes of failure including tests, if any, to be done and for such other items with a view to seeing that the equipment serves the purpose for which it is intended. Technical guidance to ensure proper operation and maintenance of the equipment shall be constantly rendered. 13. INFRA-STRUCTURE FOR QUALITY ASSURANCE The firm/manufacturer shall have the infrastructure facilities like machinery and plants and testing equipment as per Appendix " E" of the Specification. The requirements are considered essential before considering a firm for approval for manufacture and supply of the battery to the Indian Railways. In addition to the above, the firms having valid ISO 9000 certificate accreditation or equivalent for ensuring conformance to the laid down Quality System requirements for design, manufacturing process, testing , quality control at different stages of manufacturing etc. shall only be considered. 14. INFRINGEMENT OF PATENT RIGHTS Indian Railways/RDSO shall not be responsible for infringement of patent rights arising due to similarity in design, manufacture process, use of components, use in design , development and manufacture of batteries and any other factor, which may cause such dispute. The responsibility to settle any dispute lies with the manufacturer.

APPENDIX -'A' (Clause0.4)

SCHEDULE OF DESIGN PARTICULARS The following particulars are required to be supplied by the manufacturer with the quotation: S. No. DESCRIPTION PARTICULARS TO BE FILLED IN 1. Make ……………………. 2. Type of unit ……………………. 3. Manufacturers nomenclature ……………………. 4. Overall dimensions of unit ……………………. (length x width x height) 5. Mass per unit with ac id ……………………. 6. Cell container material ……………………. 7. Type of positive plates ……………………. 8. Type of negative plates ……………………. 9. Separators ……………………. 10. Maximum electrolyte temp. ……………………. That the cell / battery withstand Without any damage a) Continuously …………………….deg C b) For a short period …………………….deg C 11. Electrolyte height above …………………….mm the top of separators 12. Electrolyte height below …………………….mm the bottom plates 13. Quantity of electrolyte ……………………. Liters per cell 14. Sp. Gr. of electrolyte for initial ……………………. filling at 27 deg. C 15. Details of initial treatment ……………………. Recommended 16. Material of terminal and ……………………. inter - cell connectors 17. Normal Charging Rate …………………….Amps 18. Frequency of topping up …………………….months 19. Inter cell connector size …………………….sq., mm.

APPENDIX 'B' (Clause 0.4)

SCHEDULE OF PERFORMANCE S. No. DESCRIPTION PARTICULARS TO BE FILLED IN 0.0 Batteries offered according to this standard shall be covered by a type approval certificate from an appropriate authority. All variations in the design shall be covered by a separate type approval certificate. Following particulars regarding the type tests shall be supplied by the manufacturer along with the certificate against any quotation or tender. 1. C-10 Ampere -hour capacity (actual /declared) …………………….Ah 2. Ampere hour efficency …………………….percent 3. Watt hour efficieny …………………….percent 4. Retention of charge …………………….percent 5.Life …………………….units 6.Storage …………………….Ah 7.Rise in electrolyte temp above the …………………….deg. Cent ambient air temp. when charged from dully discharged to fully charged conditions at normal rate. 8. Charge and discharge curves with voltage ……………………. Versus time showing the performance of the Cell for discharge at 10 hours rate and charge at Normal rate 9. Loss of water …………………….gm/Ah

APPENDIX"C" SEQUENCE OF TYPE TESTING

-------------------------------------------------------------------------------------------------------- TEST SAMPLE NUMBER 1 2 3 4 5 6 7 8 9 -------------------------------------------------------------------------------------------------------- a(*) Checking of dimensions, x x x x x x x x x mass, markings and workmanship b. Capacity at 10hrs. rate x x x x x x - - - c. Material and component - - - - - - - - x specification verification test d. Air Pressure - - - - - - x x - e Storage - - - - - - x x - f. Life - - x x - - - - - g. Watt hour and Ampere - - - - x x - - - hour efficiency h. Retention of Charge - - - - x x - - - i. Equilibrium float current x x - - - - - - - j. Water loss x x - - - - - - - k. Sealing of container x x with lid (*) Mass to be checked for sample numbers 1 to 6 (x) Samples to be subjected for tests NOTE: The cell of new design shall be prototype tested for which samples offered by the manufacturer shall be accepted. The cells shall be re-type tested every 5 year for revalidation and the samples shall be drawn from mass production at random. In case of unsatisfactory performance of cells in field, re-type testing can also be done earlier at the discretion of the approving authority.

APPENDIX "D" (Clause 5.5.5)

SAMPLING PROCEDURE FOR ACCEPTANCE TESTS D.1 LOT D.1.1 In the consignment, all the cells of the same rating manufactured from the same material under similar conditions of production shall be grouped together to constitute a lot. D.1.2 These cells in the sample shall be drawn from the lot at random. For the purpose of random selection, reference may be made to IS: 4905- 1968 D.2 SAMPLE SIZE AND CRITERIA FOR CONFORMITY D.2.1 The acceptance tests shall be conducted on minimum two samples upto a maximum of 1 percent of each type in a lot, the samples being drawn at random by the purchasing or inspecting authority as specified in clause 5.1.3.1 Appendix 'G' in Amendment NO. 1 of IS:6848-79 latest D.2.2 Criteria for Acceptance if any of the samples cells fail in any of the acceptance test, twice the original number of samples shall be taken and subjected to all the acceptance tests. If there is failure in re-test, the lot may be rejected.

APPENDIX "E"

LSIT OF MACHINERIES AND PLANTS FOR MANUFACTURE OF LOW

MAINTENANCE LEAD ACID STORAGE CELL ESSENTIAL MANUFACTURING FACILITIES

1. Lead antimony alloying plant to have alloy with different antimony percentages 2. Lead oxide manufacturing mill (a) Lead Peroxide manufacturing Plant. 3. Pressure die-casting machines f or Positive /Negative grids (Hand molding process not permitted) (a) Die- casting machines for terminal post, inter cell connectors , poles etc,. (Hand molding process not permitted) 4. Automatic pasting plant for negative plates (Hand pasting process not permitted) (a) Automatic paste mixing plant (Manually not permitted) 5 Vibration plant for filling of positive tubular plates 6. Positive tube bag manufacturing plant 7. Separator manufacturing plant 8. Container manufacturing plant with computer controlled rubber mixing for making container 9 Plate formation plant 10. Jigs and fixtures to make groups of positive and negative plates 11. Bitumen compound sealing plant with thermostat 12. Chemical Laboratory to test various chemical ingredients. 13 Gas burners set for assembly of positive and negative group plates for battery . 14. Distilled water manufacturing plant 15 Container top lid- manufacturing plant 16 Container and top lid manufacturing plant for PPCP material 17. Heat sealing plant for PPCP cells 18. Compressor with dryer 19. Humidity chamber 20. ISO 9000 certificate ADDITIONAL PLANT AND MACHINERY (a) Air pollution control system (b) Water effluent plant (c) Water sera beer for formation room (d) Fork lift (e) Pallet truck (f) Formation rectifier (g) DG Sets

ESSENTIAL LIST OF TEST EQUIPMENT

1. C10 test conducted by computerized control battery charging /discharging equipment with monitoring and recording system (Manually not permitted) 2 Fully computerized control life cycle testers with logging , monitoring and recording system (Recording time, voltage, min. 6 channels , current m, temp , Ah, Wh, mode and cycle step) 3. Temperature controlled test room 4.Carbon pile loads of different capacity 5. Container testing facilities as per IS -1146 . (i.e. High Voltage tester, Plastic yield test apparatus, Electro magnetic ball drop test apparatus Izod impact tester, tensile testing machine, digital and chemical testing arrangements etc. ) 6. Digital ammeter, voltmeter and thermometer of different ranges 7. Measurement facility for pore size of separators 8. Battery/cell internal resistance meter 9. Sulphuric acid and distilled water testing facilities as per IS specifications 10. Multimeter digital (Min. DCV 1000 V, ACV -750 V DC 10A, R- 2 mega Ohm)

ADDITIONAL LIST OF TEST EQUIPMENT 1. Thermostatically control rolled tank for life cycle units. 2. Separator testing apparatus as per IS 6071 3. Bitumen sealing compound testing apparatus as per IS 3116 4.Distilled water testing arrangements as per IS 1069 5. Microporous vent plug testing arrangement (i.e. Electromagnetic ball drop apparatus, weighting digital top pan balance capacity 100 gms +- 0.05 gms, fire retardant test apparatus, permeability test apparatus etc. ) 6. Heating apparatus 7. Electronic Balances(capacity 50gms with decimal second digit) 8. Shore hardness meter 9. Manometer 10. Air pressure tests arrangements 11. Polarity testing arrangements 12. Short circuit testing arrangements.

ESSENTIAL LIST OF TEST EQUIPMENT.

APPENDIX –“F” LIST OF MACINERIES AND PLANTS FOR MANUFACTURE OF LOW MAINTENANCE LEAD ACID STORAGE CELL ESSENTIAL MANUFACTURING FACILITIES. 1. Lead antimony-alloying plant to have alloy with different antimony percentages 2. Lead-oxide manufacturing mill.

(a) Lead peroxide manufacturing plant. 3. Pressure die-casting machines for Positive/Negative grids (hand moulding process

nor permitted) 4. Automatic pasting plant for negative plates.(Hand pasting process not permitted)

(a) Automatic past mixing plant(Mannually not permitt 5. Vibration plant for filling of positive tubler plates. 6. Positive tube bag manufacturing plant. 7. Separator manufacturing plant. 8. Container manufacturing plant with computer controlled rubber mixing for making

container. 9. Plate formation plant. 10. Jigs and fixtures to make groups of positive and negative plates. 11. Bitimen compound sealing plant with controlled thermostat, 12. Chemical laboratory to test various chemical ingredients. 13. Gas burners set assembly of positive and negative group plates for batery. 14. Distilled water- manufacturing plant. 15. Container top lid –manufacturing plant. 16. Compressor with dryer. 17. Acid filling machine. 18. Humidity chamber. 19. Acid chilling plant. 20. ISO: 9000 Certificate.

ADITIONAL LIST OF PLANT AND MACHINERY (a) Air pollution control system (b) Water effluent plant. (c) Water serabeer for formation room. (d) Fork lift. (e) Pallet truk. (f) Formation rectifier. (g) DG sets.

APPENDIX – “E” (Clause.5.9)

TEST PROCEDURE FOR AMPERE-HOUR & WATT –HOUR EFFICIENCY C.1 The following method shall be used for determining the maximum ampere-hour and watt-hour effciencies. a. Ampere-hour efficiency: A fully charged battery shall be discharged at 1=0 I x C10 amperes to a end voltage of 1.80 x n volts, careful measurements being made of exact number of ampere hour deliverd. On the recharge the same number of amperehours are put back at the same current. A second discharge shall then be made to the same cut off voltage as before. The efficiency of the battery is then calculated as the ratio of the ampere-hour delivered during the second discharge to the ampere-hour put in on the charge. b. Watt-hour efficiency : The watt-hour efficiency shall be calucated by multiplying the ampere-hour efficiency by the ratio of average discharge and recharge voltages. The Values of discharge and recharge voltage shall be calculated from the log sheets for ampere-hour efficiency.

AOOENDIX “C” (Clause 5.5)

SEQUENCE OF TYPE TESTING

TEST SAMPLE NUMBERS 1 2 3 4 5 6 7 8 9 a (*) Checking f dimensions, X X X X X X X X X mass, markings and workmanship b. Capacity at 10 hrs rate X X X X X X X X X c. Material and component specofication -- -- -- -- -- -- -- -- X

Verification test. d. Air Pressure. -- -- -- -- -- -- X X -- e. Storage -- -- -- -- -- -- X X --

f. Life . -- -- X X -- -- -- -- -- g. Watt-Hour and Ampere-hour efficiency. -- -- -- -- X X -- -- -- h. Capacity at 5 hr. rate -- -- -- -- X X -- -- -- i. Capacity at 3 hr rate -- -- -- -- X X -- -- -- j. Retention of charge. -- -- -- -- X X -- -- -- k. Equilibrium float current. X X -- -- -- -- -- -- -- l. Water loss X X -- -- -- -- -- -- -- m. Vibration. X X -- -- -- -- -- -- -- (*) Mass to be checked onlyfor sample number 1 to 7. (X) Samples to be subjected for tests. NOTE : The cell of new design shall be prototype tested for which samples offered by the manufacture shall be accepted. The cells/batteries shall be re-type tested every 5 years for revalidation and the samples a shall be drawn from mass production at random in case of unsatisfactory performance of cells in field. Re-type testing can also be done earlier at the discretion of the approving authority.

APPENDIX “D” (Clause 5.5.5)

SAMPLING PROCEDURE FOR ACEPTANCE TESTS D.1 LOT D.1.1 In the consignment, all the batteries of the same rating manufactured from all same material under similar conditions of production shall be grouped together to constitute a lot. D.1.1.1 These batteries in the sample shall be drawn from the lot at random For the purpose of random selection, reference may be made to IS:4905-1968 D.2 SAMPLE SIZE AND CRITERIA FOR CONFORMITY D.2.1 The acceptance tests shall be conducted on minimum two samples up to a maximum of 1 percent of each type in a lot,the samples be ing drawn at random by the purchasing or inspecting authority as specified in clause 5.1.3.1 Appendix “G” in Ammendment No.1 of IS:6848-79. D.2.2 Criteria for Acceptance if any of the samples batteries fail in any of the acceptance test. Twice the original number of samples shall be taken and subjected to all the acceptance tests. If there is failure in re-test, the lot may be rejected.

APPENDIX “A”

(Clause 0.3)

SCHEDULE OF DESIGN PARTICULARS

The following particulars are required to be supplied by the manufacturer with the quotation. S.No. DESCRIPTION PARTICULARS TO BE FILLED IN 1. Make. ---------------------------------------------

-- 2. Type of unit. --------------------------------------------

--- 3. Manufacturers nomenclature. --------------------------------------------

--- 4. Overall dimensions of unit. --------------------------------------------

--- (Length x width x height)

5. Mass per unit with acid. -----------------------------------------------

6. Cell container material. -----------------------------------------------

7. Type of positive plates. -----------------------------------------------

8. Type of negative plates. -----------------------------------------------

9. Separators. -----------------------------------------------

10. Maximum electrolyte temp. ----------------------------------------------- That the cell/battery withstand. Withour any damage. a) Continuously. -------------------------------------

deg.C b) For a short period. ------------------------------------deg.C

11. Electrolyte height above ------------------------------------------mm The top of the separators.

12. Electrolyte height below the Bottom plates. ------------------------------------------mm 13. Quantity of electrolyte liters per cell. ------------------------------------------

----- 14. Sp.Gr.of electrolyte for initial. ------------------------------------------

-----

Filling at 27 deg.C.

15. Details of initial treatment recommended.-----------------------------------------------

16. Material of terminal and inter- cell connectros.---------------------------------------------

17. Normal chargeing rate. -----------------------------------Amps

18. Frequency of topping up. --------------------------------Months

APPENDIX “B” (Claaause 0.3)

SECHEDULE OF PERFORMANCE

S.No. DESCRIPTION PARTICULARS TO BE FILLED IN

0.0 Batteries offered according to this

Standared shall be covered by a type Approvel certificate from an appropriate Authority. All variations in the design shall Be coverd by a separate type approval Certificate. Following particular regrding the Type tests shall be supplied by the Manufacturer along with the certificate Against any quotation or tender.

1. Amper-hour capacity ( Actual) (a) C10 ------------------ percent (b) C5 ------------------ percent (c) C3 ------------------ percent

2. Amper-hour efficiency ------------------ percent 3. Watt-hour efficiency ------------------ percent 4. Retention of charge ------------------ percent 5. Life --------------------- Units 6. Storage --------------------------Ah 7. Rise in electrolyte temp above the

Ambient air temp. when charged From dully dicharged to fully charged Conditions at normal rate -----------------deg.Cent.

8. Charge and discharge curves with

Voltage versus time showing the Performance of the cell for discharge At 10 hours rate and charge at normal rate. --------------------------

9. Loss of water. ------------------grm/ah 10. Equilibrium float current. ------------------ ma/ah