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Page 1 of 23 Specification No. RDSO/PE/SPEC/TL/0040 (Rev.2) -2021

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

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RESEARCH DESIGNS AND STANDARDS ORGANISATION

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SPECIFICATION FOR LOW MAINTENANCE LEAD ACID 40 AH, 150 AH, 200 AH

AND 250 AH CELLS FOR TRACTION DISTRIBUTION SYSTEM

No. RDSO/PE/SPEC/TL/0040 (Rev.12) -200321

S.No. Date of Revision/

amendment Revision/Amend

ment Page No.

Reasons for revision

1. 19.08.2019 Rev ‘1’ 23 Hard Rubber Container/Lid Deleted. New drawing for float guide, fasteners for 40 Ah, revalidation test and marking added. Microporous vent plug clause amended.

2 ……… Rev ‘2’ 23 150Ah cell for SSP/SP and 250 Ah cell for TSS for high speed route, included with its dimensions and weight. Other clauses accordingly revised and corrected

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APPROVED

Ikz/kku dk;Zdkjh funs'kd@fo|qr vkiqfrZ ,oa bZ-,e-;w- Principal Executive Director/ Power Supply & EMU


Prepared By: JE/PE & Battery

Verified By: DSE/MRVC

SPECIFICATION FOR LOW MAINTENANCE LEAD ACID 40 AH, 150 AH, 200 AH 250AH CELLS FOR TRACTION DISTRIBUTION SYSTEM.

1.0 FOREWORD:-

1.1 In 25 kV, Traction Distribution System in Indian Railways (IR), 2V, 40Ah and 2V, 200Ah capacity LMLA cell are used for installations in the control rooms at unattended switching stations and traction sub stations. For the Rail routes where speed potential is up to 160 kmh (NDLS-HWH & NDLS-BCT), the 150Ah cells for SSP/SP and 250 Ah cells for TSS are to be used.

1.2 The cell for traction sub-stations and switching stations shall be of single cell construction and 55 Nos. cells constitute one set.

1.3 All types of traction sub-stations and switching stations shall be provided with single set of 55 Nos. cell.

1.4 The rated capacity of the entire cell shall be at 10 hour rate at 27 °C 2V, 40Ah for SSP/SP switching stations &2V, 200 Ah for traction sub-stations at 27 degree centigrade.

1.5 In the preparation of this specification assistance has been drawn from the following publications.

2.0 SCOPE:-

2.1 This specification covers the design, method of testing and other requirements of low

maintenance lead acid stationery cells for installation in the control room at un -

S. N. Specification Title I. IS:266-1993 with latest

amendment Specification for Sulphuric Acid

II. IS : 6848-1979 with latest amendment

Specification for Lead Acid Batteries for Train Lighting and Air Condition services

III. IS:1069-1993 with latest amendment

Specification for Quality Tolerances for Water for Storage batteries

IV. IS : 8320-2000 with latest amendment

Specification for General Requirements and Methods for Test of lead acid Storage Batteries

V. IS:4905:1995 Specification for Method for Random Sampling

VI. IS : 1146 – 1981 with latest amendment

Specification for Rubber and Plastic Container for Lead Acid Storage Batteries

VII. IS:6071-1986 Specification for Synthetic Separators for lead-acid Batteries

VIII. IS:1651-1991 with amendment No. 1

Stationary Cells and Batteries, Lead Acid Type (with tubular Positive Plates) -Specification

IX. IEC 60896-11 Stationary Lead Acid Batteries, Vented Types- General Requirements and methods of tests

X. IS: 1248-2003. Direct Acting Indicating Analogue Electrical Measuring Instruments and their Accessories

XI. RDSO Spec. No. TI / SPC/PSI/ 200-250/CHGR/0210- Battery charger for 110Volt battery, 200/250 Ah at Traction Sub-station for 25kV/2 X 25 kV Electric Traction Installation.

XII. RDSO Spec. No. TI / SPC/PSI/ 40-150/CHGR/1210- Battery charger for 110 Volt battery, 150 Ah (for 2X25 kV) and 40 Ah (for 25 kV) at SP/SSP for Electric Traction Installation.




attended 132/25kV or 220/25kV traction sub stations (TSS) and at un-attended sectioning and paralleling posts (SPs) and sub-sectioning and paralleling posts (SSPs). The cell shall be of low maintenance design such that it requires very less topping up in the service. Frequency of topping up shall not be earlier than 9 months.

2.2 The cell 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 within the scope of this specification.

2.3 The cell shall be delivered in the dry uncharged condition and ready for filling the electrolyte and use at site. Sufficient quantity of electrolyte required for initial filling, with 10% extra shall be supplied separately in non-returnable containers.

3.0 TERMINOLOGY:-

3.1 TYPE TESTS:-. These are intended to prove the general quality and design of a given type of battery.

3.2 ROUTINE TEST:- Test carried out on samples to check the conformity of specification and approved type test value.

3.3 REVALIDATION TEST:- Test carried out on samples after modification in approved design or on samples offered for superior design.

3.4 ACCEPTANCE TESTS: - Tests carried out on samples selected from a lot for the purpose of verifying the acceptability of the lot.

3.4.1 LOT: - All batteries/cell 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.

3.5 ELECTROLYTE: - Aqueous solution of sulphuric acid for ionic conduction and Electro-chemical reaction during passage of current through a cell.

3.6 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.

3.7 FLOAT GUIDE:-A removable bush of anti-splash and sealed type to facilitate easy vertical movement of float stem for indicating the level of electrolyte in the cells.

3.8 MICROPOROUS VENT PLUG: -A removable anti-splash plug for fitting into the hole on lid for free escape of gases during charging.

4.0 MATERIAL AND CONSTRUCTION:-

4.1 All Cells shall be of same standard in shape and design. Provision shall be made to lift/hold the cells with suitable strength for 40Ah cell. and 200Ah Cell.Molded or rope handle shall be provided on container for 150Ah, 200 Ah and 250 Ah cell. The material and construction of cell shall be as per approved designed.

4.1.1 The cell shall be so designed that the initial charging of the cell shall be completed within 75 hours as per the charging method prescribed by the manufacturers and accepted by the type testing authority. Subsequent charging for conducting various




tests shall be restricted to 15hours. Initial charging and normal charging details shall also be mentioned in the Maintenance Manual.

4.1.2 All the positive or negative plates shall be insulated at edges to avoid side shorting. For this purpose PE envelop type separator may be used.

4.2 OVERALL DIMENSIONS:-

4.2.1 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: 1651-2013*. The dimensions do not include the projection of float guide or vent plug.

*The final size of battery will be standardized by RDSO.

4.2.2 The maximum weight of the cell with the electrolyte shall be 40 Kg, 31 Kg, 25 Kg and 10 Kg for 250 Ah, 200Ah, 150Ah and 40 Ah cell respectively.

4.3 PLASTIC CONTAINER/CELL LIDS:- 4.3.1 The cell shall be supplied with plastic containers / lids. The container/lid shall have

adequate strength with design margins to meet the actual field conditions prevalent over Indian Railways for which battery manufacturers shall be wholly 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, 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 container/lid as approved by the RDSO, free of cost within the warranty period.

Container/lid may have strengthening member/rib inside or outside of the container/lid. However the overall outer dimension shall not exceed the values as per table 1 of clause 7.1 of IS: 1651-2013. The 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 than 3.0 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. Acid resistance test. 6. Izod impact test




4.4 FLOAT GUIDE AND VENT PLUG CUM FLOAT GUIDE:- 4.4.1 In order to have standardization, the float guide applicable for TL&AC coaches

batteries shall be used for 150Ah, 200 Ah and 250Ah cells Batteries conforming to drawing No. RDSO/PE/SK/0058-03 (Rev ‘1’).For 40 Ah cell vent Plug cum float guide shall be used conforming to drawing No RDSO/PE/SK/TL/0209-2019 (Rev.0).

4.4.2 The Microporous body of Vent plug cum float guide for 40 Ah Cells shall be made of ceramic or any other suitable fire retardant material. Test shall meet the clause 4.5

4.5 MICROPOROUS VENT PLUG:-

4.5.1 Each cell of 150Ah, 200 Ah and 250Ah shall be provided with the microporous vent plug for venting of gases and for servicing of the electrolyte and shall generally conform to RDSO drawing No. SKEL- 4020/A Alt.3. Dome/Filter of vent plug shall be made of ceramic or any other suitable fire retardant material. The vent 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 plug, servicing and checking of electrolyte shall be possible.

4.5.2 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 and dent. The dome shall be taken out from plastic body for the following tests.

a) Porosity: Porosity of micro-porous filter shall be 35 ± 5% when 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 minutes. Weigh the sample in water (W2). Next weigh the wet sample outside the water (W3). Calculate porosity as under:

(W3-W2)- (W1-W2) Porosity% = -----------------------------X100

(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 once on side of micro-porous dome. This test is not applicable on dome for 40 Ah Cell

c) Acid resistance: Dry and weigh the (micro-porous body) dome (W1), Keep the dome in sulphuric acid of Sp.Gr.1.3at40 °C for 100 hours. Remove it from acid, wash free of acid dry and weight (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 charged cell shall be fitted with vent plug and charged at 2.5times of C10 rate for 4hours.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) Plastic Component: Plastic body of the micro-porous dome shall be free from crack, flash, pin hole, air bubble, uneven shrinkage foreign particles etc. and shall conform to the following:

i) Material: ABS Fire retardant or superior quality ii) Acid Resistance: No perceptible change iii) Heat: No deformation at 70°C

4.5.3 DIA AND PITCH THREAD:- The micro-porous vent plug, sealed float guide and

vent plug cum float guide dia shall be 27 mm and pitch of thread shall be 3 mm. Cell 150 Ah, 200Ah and 250Ah 200 Ah cell shall have two vent hole, one for sealed float guide and another one for vent plug, whereas 40Ah cell shall have one vent hole for micro porous vent plug cum sealed float guide.

4.6 TERMINAL: Each cell of 150 Ah, 200Ah and 250Ah (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 12 mm minimum. 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)

4.6.1 Positive and Negative terminal for 40 Ah shall be easily distinguishable and shall have single hole with minimum thickness of 5 mm.

4.7 INTER -CELL AND END –CELL CABLE CONNECTORS:

4.7.1 Inter -cell cable connectors required for supply for one set (consisting of 55 cells)are given below.

i) Inter cell cable connector = 52numbers

ii) Inter row cable connector = 2 numbers (Cell No. 14-15 and42-43)

iii) Take off terminal = 2 numbers (End cells)

iv) Interior cable connector = 2 numbers (Cell No. 28 &29)

v) Fasteners(250Ah) = 220numbers

vi) Fasteners(200Ah) = 220numbers

vii) Fasteners(150Ah) = 220numbers

viii) Fasteners(40Ah) = 110 numbers

The fasteners of size M6x25 or 30 for 40 Ah and M8x30 or 35 for 150 Ah, 200Ah and 250Ah cells 200 Ah Cells shall be used.

4.7.2 The crimping Lug of cable connectors shall have the lead coating to withstand the 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 &3or latest.

4.7.3 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 (Rev.II)-1993 Part I &II or latest.




4.7.4 The crimping of lug with cable 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 16/18 Sq. mm for 40Ah and 40/50sq. mm for 150 Ah, 200Ah and 250Ah 200 Ah respectively shall be used.

4.7.5 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 shall not be provided with lead coating.

4.8 ELECTROLYTE:-It shall be prepared from battery grade sulphuric acid conforming to IS: 266-1993 with latest amendment.

4.8.1 The specific gravity of electrolyte in fully charged condition when corrected at 27°C shall be 1.215±0.005. The specific gravity shall be corrected to27°C by applying formula as given under the clause. 3.2.2 of IS: 8320-2000 or latest.

4.9 WATER: - The water used for topping up and preparing electrolyte shall conform to IS: 1069-1993

4.10 SEPARATOR:- Separator shall be Micro porous rubber/ PVC/ PE or any other superior material conforming to IS:6071-1986. The volume porosity shall not be less than35%. For wet ability test, the complete wetting of PE separator shall be within 10 minute duration.

4.11 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.

4.11.1 Electrical insulating grade and acid resistant 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.

5.0 ENVIRONMENTAL & SERVICE CONDITIONS: - The cell shall be suitable to work satisfactorily in following condition as given in table-1 below.

TABLE-1 i) Maximum ambient air

temperature 55°C

ii) Minimum ambient air temperature -5°C iii) Max. relative humidity 98% iv) Coastal area Humid, Salt laden and corrosive

atmosphere. v) Conditions in the coastal area can be as under: a. Max. pH value 8.5 b. Sulphate 7 mg/litre




c. Max. concentration of chlorine 6 mg/litre d. Max. Conductivity 130 micro Siemens/cm e. Annual rainfall Ranging between 1750 to 6250 mm with

thunder storm & lightening. vi) Altitudes (max) 1200m vii) Dust content in air (max) 1.6 mg/m3

5.1 40Ah/150Ah Cell are used 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 the power supply to the traction overhead equipment. 200Ah/250Ah batteries are used as a reliable power source for operation of switchgear and various control /indication circuits at the unattended traction sub-station.

5.2 The Cell shall be normally on trickle charge by suitable battery charger. During AC supply failure or battery charger failure the Cell shall be capable to deliver the full load for operation of the interrupters and the various control/indication circuits.

6.0 RATING AND CAPACITY:

6.1 RATED CAPACITY: The rating assigned to the cell shall be capacity at C10rate in ampere hour (after correction at 27°C) when the cell/ battery is discharged at 10 hr rate current to the end voltage of 1.85V per cell.

6.2 DECLARED CAPACITY: Since the declared C10 capacity of the cell/battery is generally higher then rated C10 capacity, the manufacturer shall declared their designed C10 capacity of the cell.

6.3 OBTAINED CAPACITY: Obtained capacity is the capacity obtained during discharge of cell up to 1.85V at 10 hours rate of the rated capacity of cell.

7.0 TESTS:-Tests shall be carried out as per table-2 given below. Type tests and revalidation test shall be conducted after 3 cycles of charge/discharge at 10 hour rate. Unless and otherwise specifically mentioned, all tests shall be conducted at the temperature of 20-32°C.

7.1 The cells after discharge, shall be charged immediately at normal charging rate i.e., I (current) =0.1xC10 Cap. or as specified by the manufacturer. Cell shall be capable to get full charge within period of 15hrs. After the charge, rest for 12-24 hours shall be given before starting the test.

TABLE-2 S.N. Test Description Clause Prototype

test Type test

Routine test

Acceptance test

1 Dimensions , Mass, Marking& workmanship

4.2 & 7.14

√ √ √ √

2 Test for Obtained Capacity at 10 hrs

7.5 √ √ √ √

3 Watt-hour & Ampere-hour Efficiency test

7.6 √ √

- -




4 Retention of charge 7.7 √ √ - - 5 Life test & Endurance test 7.8 √ - - - 6 Storage Test 7.9 √ - - - 7 Loss of water test 7.10 √ √ - - 8 Equilibrium float current test 7.11 √ √ - - 9 Air pressure test 7.12 √ √ - -

10 Material and component specification verification test

7.13 √ √ - -

11 Checking of alloy composition

7.13.2 √ √ - -

12 Test of Micro- porous vent plug

4.5 √

- - -

7.1.1 SEQUENCE OF TESTS:- The sequence of type tests and Revalidation test and the

number of samples required shall be in accordance with Appendix "C" & “C1” respectively

7.1.2 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 test shall be considered as not having passed the requirements of this standard.

7.1.3 INSPECTING AUTHORITY: - The type test sand revalidation tests as per clause 7.0 of cells shall be conducted by the representative of RDSO/Lucknow, India at the works of manufacturers at their cost.

7.2 REVALIDATION TEST: -If container material is changed or firm modify the existing approved design based on failure reported by various Railways to improve the performance or alternative superior designs is offered for consideration of approval with necessary technical justifications and benefits, in all the cases, tests as specified in table-2 shall be conducted if capacity is same (i.e. Existing declare capacity ± 3) or more and same alloy has been used.

7.2.1 Tests as specified in table-2 shall be carried out on samples. The sequence and number of samples required shall be in accordance with Appendix"C1".

7.2.2 Revalidation testing shall be carried out at manufacturer’s premises or at NABL or a Government lab or which has been accredited by an accreditation agency having data logging facility. All the costs of testing shall be borne by manufacturer.

7.3 ROUTINE TEST:-Following tests shall be conducted as routine test on sample basis to check the lot conformity as per approved design.

i) C10 capacity ii) Dimensions, mass and Marking

7.4 ACCEPTANCE TESTS: - The acceptance tests shall be witnessed by RDSO or RITES/Consignee as mentioned in the tender/purchase order. Manufacturers shall




submit in-house C-10 discharge test results along with Open Circuit Voltage after recharge along with the inspection call.

7.4.1 Tests as specified in table-2 shall be carried out on the samples picked up from lot and shall conform the respective clauses.C10 capacity test shall conform the following:

7.4.2 Capacity test at 10hrs rate according to clause 7.5 shall not have variation of more than ± 5% of the average capacity obtained during prototype testing at 27°C subject to minimum rated capacity. The weight of dry cell shall not vary more than ± 5% of the weight obtained during prototype testing subject to minimum value as specified by firm in design drawing.

7.4.3 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'.

7.5 TEST FOR OBTAINED CAPACITY AT 10 HRS. RATE:-

7.5.1 The cell 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 cell falls to1.85V/ cell.

7.5.2 During the discharge, hourly voltage readings shall be recorded until the cell/battery voltage approach 1.90 volts per cell after which the readings shall be taken every 15 minutes until the voltage falls to1.85V/cell.

7.5.3 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 °C by the following formula:-

CT The capacity at 27 °C. = -------------

1+ K (t-27) Where “CT,” is the observed capacity at average electrolyte temperature of t °C.“K” is the variation factor 0.0043. While “t” is the average electrolyte temperature during discharge (Mean value of initial and final temperature).

7.5.4 The C10capacity at 27 °C. shall not vary more than ± 3% of declared capacity.

7.6 AMPERE HOUR & WATT HOUR EFFICENCY TEST:-

7.6.1 AMPERE HOUR EFFICENCY: A fully charged cell shall be discharged at I=0.1xC10 amperes to an end voltage of 1.85 volts/cell, care full calculation being made of exact number of ampere hours delivered. On the recharge, the same numbers 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 in on the charge.

7.6.2 WATT HOUR EFFICENCY: 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. The average voltage shall be calculated from the ‘hourly’ readings of the discharge voltage but including the voltage immediately after start of discharge and last reading, namely, 1.85 V.

7.6.3 Watt hour efficiency and Ampere hour efficiency shall not be less than 80 & 95% respectively. While conducting this test a minimum rest of 12 to 24 hours shall be given between each charge/discharge.

7.7 TEST FOR RETENTION OF CHARGE:-

7.7.1 The object of this test is to determine the loss of capacity of a cell on open circuit during a specified period.

7.7.2 The cell unit shall be subjected to two consecutive capacity test discharges in accordance with clause 7.5, the value of the initial capacity, ‘C’ being calculated as the mean of the two results thus obtained at 27 °C.

7.7.3 After a complete recharge and after cleaning the surface, the battery shall be left on open circuit for a period of 14 days without disturbance at ambient temperature.

7.7.4 After14 days of storage, the cell shall be discharged in accordance with clause 7.4. The value of the capacity measured at 27 °C after storage shall be denoted by C1.

7.7.5 The loss of capacity shall be calculated from the following formulae. C- C1 S= ----------- X100 C 7.7.6 REQUIREMENT: The loss of capacity shall not be more than 3% over 14 days of

storage period.

7.8 LIFE TEST:-

7.8.1 The life test shall be conducted as per clause 12.8(Endurance test) of IS: 1651-2013 applicable to normal cells.

7.8.2 REQUIREMENT:-The minimum duration of discharge at10 hr. rate shall be 10 hr. till the end cell voltage of 1.85V”.

7.9 STORAGE TEST:- 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 7.5.

7.9.1 The capacity after 24 months, when tested as above shall not be vary more than ± 3 of the obtained capacity.

7.10 LOSS OF WATER TEST:-

7.10.1 After full charge, the cell/battery shall be cleaned and dried. It shall be weighed with vent cum-filling plugs immediately but not exceeding one hour after drying with an accuracyof0.05% or with maximum least count of 20gm for the balance used. Thereafter cell shall be connected to constant voltage charger keeping the voltage 2.4/cell ±0.05 volts for 21 days in water bath/hot chamber at the temperature of 50±2 °C. On the completion of 21 days the cell shall be removed from circuit and dried.




After cleaned and dried it shall be weighed accurately.

7.10.2 The water loss shall not exceed 0.8gm/Ah/cell of the obtained capacity.Water topping up interval shall not be less than 9 months based on water loss achieved in 21 days

7.11 EQUILIBRIUM FLOAT CURRENT TEST:-

7.11.1 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/cell ±0.05 volts. The float current shall be measured and recorded. It shall not be more than 3mA/AH of the obtained C10 capacity.

7.12 TEST FOR AIR PRESSURE:-It shall be carried out on all the dry cells to ensure the sealing strength and to check the leakage in the cells.

7.12.1To check the leakage and sealing strength of the cell, compressed air at the pressure of 5-6 psi shall be applied for 1 minute. The cell lid shall not show any visible sign of movement due to the air pressure and drop in pressure due to leakage. To detect the leakage, cell may be immersed in water bath.

7.12.2 Cell shall be checked 100% in bulk production at the pressure of 4-5 PSI for 15 seconds.

7.13 MATERIAL AND COMPONENT SPECIFICATION VERIFICATION TEST:-

7.13.1 The cell shall be examined in the dismantled condition to see that the various components and assembly drawing are conforming to the specification. The samples of separator, container, acid and water shall be taken at random from the manufacturing line and tested to see that they meet the requirements of the relevant specifications.

7.13.2 CHECKING OF ALLOY COMPOSITION:- Firm shall furnish the report of alloy composition of positive spine and negative grid by optical emission spectrometer (O.E.S.) from own or govt. approved laboratory.

7.14 MARKING & WORKMANSHIP:-

7.14.1 Marking - On the top lid or container wall, following details shall be embossed:- Manufacturer's name or trade mark and rating at 10 Hr rate.

7.14.2 Both the shorter or longer sides of such container shall have the following detail stencil on the container by acid proof paint:-

i) Manufacturer's name or trademark ii) Rating at 10 hrs. discharge rate and

iii) Specific gravity of the electrolyte in the fully charged condition at 27±2 °C

iv) Place of manufacturing

Note: STICKER not permitted on cells.

7.14.3 The year and month of manufacture shall be punched on the terminal lug base.

7.14.4 Manufacture name or trademark and rating of battery may be embossed on the connector if markings are not possible to emboss on lid or in PPCP container.




7.14.5 Place of manufacturing along with above details shall be provided either shorter or longer side of container by legible and durable screen printing with acid resistance paint or embossed /engraved.

7.14.6 Workmanship:- The container shall be from any cracking or chipping or distortion and any sign of leakage or spillage.

8.0 TEST EQUIPMENTS:-

8.1 The voltmeters, Ammeters, Thermometer and Hydrometer etc. required for the tests as 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. All the tests shall be conducted with data recorders with continuous logging facility of voltage, current, AH input/output with reference to time. Manual recording is not permitted.

9.0 DRAWING:-

9.1 The manufacturer shall supply two sets of drawing in A4 size listed as 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

(d) General arrangements of drawings of 55 cells of a set indicating connections from cell to cell.

(e) Any other drawings considered relevant.

9.2 After the prototype approval by RDSO, no design change shall be undertaken by manufacturer on cells/ batteries without prior approval of RDSO, failing which the approval may be withdrawn by RDSO at any time.

10.0 PACKING AND DISPATCH:-Manufacturers shall be responsible for safe transportation and delivery of cells in good condition to consignee. If there is any damage of cells during transportation manufacturer shall replace it free of cost.

11.0 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 set. The tool Board shall comprise:-

i. One Syringe for adding or taking out electrolyte from the cells.

ii. One hydrometer of requisite range with a graduated scale for measuring the specific gravity of electrolyte of the cells, one division of which shall represent the 0.005 unit of specific gravity with accuracy of calibration not less than 0.005 units.

iii. One digital multi meter

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 1°C.

12.0 RELIABILITY:- 12.1 If considered necessary, RDSO may undertake re-testing of some or all prototype

tests as per specifications at any time to ensure proper effective quality control being exercised by the manufacturer at different stages of manufacturing.

12.2 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.

13.0 DESIGN DOCUMENTS AND INSTRUCTIONSMANUAL:-

13.1 Following documents in the spiral bound form shall be submitted to the RDSO.

a) One set of drawings as per clause 9.0 of this specification andin house test results and related details as per appendix 'A' and 'B. before offering the type test

b) After completion of tests following documents in spiral bound form shall be submitted in duplicate.

i) Bill of Material

ii) ISO Certificate with letter of issuingauthority

iii) Drawings

iv) Prototype test results

v) Quality assurance plan (QAP) as per RDSO’s ISO format.

vii) Maintenance manual in soft and hard copy.

13.2 Notwithstanding the above recommendations, manufacturer is wholly and completely responsible for performance, 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.

14.0 AFTER SALESSERVICE:-

14.1 The manufacturer shall make necessary arrangements for closely monitoring the performance of equipment through periodical (preferably once in two months during the warranty period) visits to the location where the cells 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 kept readily available to meet exigencies warranting replacement so as to keep the equipment in service with least down time.

14.2 The manufacturer shall respond promptly to any call given by Indian Railways for any assistance by way of attending to failures. Investigation into the cause of failure includes review tests to be done with part/components with a view to see that the equipment serves the purpose for which it is intended. Technical guidance to ensure proper operation and maintenance of the batteries shall be constantly rendered.

15.0 INFRINGEMENT OF PATENTRIGHTS:-

15.1 Undertaking to be signed and submitted by vendor along with application for registration as per RDSO’s ISO document No: QO-F-8.1-7 of latest version (available on RDSO’s official web-site).

Undertaking to be signed and submitted by vendor at the time of registration with application form along with annexures as per RDSO ISO document.(Available on RDSO’s official website)




APPENDIX-'A'

(Clause13.1) 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 …………………….mm

(length x width x height)

5. Mass per unit with acid …………………….Kg 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.




SCHEDULE OF PERFORMANCE

APPENDIX'B' (Clause13.1)

S.No. DESCRIPTION PARTICULARS TO BE FILLEDIN

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 efficiency ....................................................................... %

3. Watt hour efficiency ............................................................................ %

4. Retention of charge .............................................................................. %

5. Life ....................................................................................................... units

6. Storage ................................................................................................. Ah

7. Rise in electrolyte temp above the......................................................... ..°C

ambient air temp. when charged from dully discharged to fully charged conditions at normal rate.

8. Charge and discharge curves withvoltage ……………………. 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" (Clause 7.1.1)

SEQUENCE OF TYPE TESTING

NOTE:. 1. (*) Filled Mass to be checked for sample numbers 1 to 8 2. (x) Sample to be subjected for tests. 3. Sample number 9 shall be dry unfilled cell

Test Sample No. 1 2 3 4 5 6 7 8 9

1

Checking of dimensions, mass, markings and workmanship

x x x x x x x x x

2 Capacity at10hrs. rate x x x x x x - - - 3 Watt hour and Ampere hour

efficiency - - - - x x - - -

4 Retention of Charge - - - - - - x x - 5 Storage - - - - - - - x 6 Life x x - - - - -

7 Loss of Water Test x x - - - - - 8 Equilibrium float current x x - - - - - - - 9 Air Pressure - - - - - - x

10 Material and component Specification verification test

- - - - - - - - x

11 Checking of Alloy composition - - - - - - - - x




APPENDIX“C1”

(Clause 7.2.1)

SEQUENCE & NUMBER OFSAMPLE FOR REVALIDATION TESTS

SN TEST Sample No.

1 2 3 4 5 6 7

1. Checking of dimensions, mass*, markings and workmanship

x x x x x x x

2 Capacity at10hrs. rate x x x x x x - 3. Watt-hour & Ampere-hour Efficiency test - - - - x x - 4 Retention of Charge - - x x - - - 5 Water Loss x x - - - - - 6. Equilibrium float current x x - - - 7 Air Pressure - - - - - - x

8 Verification of Material and Components specification - - - - - - x

9. Checking of Alloy composition - - - - - - x

NOTE:. 1. (*) Filled Mass to be checked for sample numbers 1 to 6 2. (x) Sample to be subjected for tests. 3. Sample number 7 shall be dry unfilled cell

APPENDIX "D" (Clause 7.4.3)

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 alot.

D.1.2 These cells in the sample shall be drawn from the lot at random. Forthe purpose of random selection, reference may be taken from IS: 4905-1968

D.2 SAMPLE SIZE AND CRITERIA FORCONFORMITY

D.2.1 The acceptance tests shall be conducted on minimum two samples or as specified in appendix “G” in Amd.No.1 of IS: 6848.

D.2.2 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.













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