Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010

Project Name: Date: 01 Apr 2011

Contract Number: Page 1 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

This specification has been revised as indicated below and described in the revision record on the following
page. Please destroy all previous revisions.

Revision Date Originator's Reviewed/Checked By Pages

No. Name & Initials Name & Initials

A 7/27/2010 Bob Henry Joe Seymour 3

0 9/28/2010 Bob Henry Joe Seymour 9
1 4/1/2011 Wayne Kanemitsu Bob Henry 11

APPROVALS SIGNATURES DATE

Lead Engineer
Project Manager:
Client Approval:

ISSUED FOR : Construction X Other Approved

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 2 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

Record of Revisions
Revision Date Description
No.

A 7/27/2010 Issued for Approval, Table of Contents Only

0 9/28/2010 Issued for Review/Approval

1 4/1/2011 Issued Approved

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 3 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

TABLE OF CONTENTS

1.0 GENERAL .....................................................................................................................................................4

1.1 Summary..........................................................................................................................................4
A. Scope of Specification ........................................................................................................4
B. Related Documents.............................................................................................................4
1.2 References........................................................................................................................................4
2.0 PRODUCTS...................................................................................................................................................5
2.1 General.............................................................................................................................................5
2.2 Equipment .......................................................................................................................................5
A. Battery Bank .......................................................................................................................5
B. Battery Charger...................................................................................................................7
2.3 Design Criteria ................................................................................................................................9
A. Battery Sizing Criteria ........................................................................................................9
B. Battery Charger Sizing Criteria ..........................................................................................9
2.4 Finish................................................................................................................................................9
2.5 Identification and Tagging ............................................................................................................9
2.6 Inspection and Tests........................................................................................................................9
A. Routine Tests ....................................................................................................................10
B. Special Tests .....................................................................................................................10
C. Witnessed Tests ................................................................................................................10
D. Test Reports......................................................................................................................10
2.7 Preparation for Shipment.............................................................................................................10
3.0 EXECUTION...............................................................................................................................................11

4.0 ATTACHMENTS........................................................................................................................................11
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 4 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

1.0 GENERAL

1.1 Summary

A. Scope of Specification

This specification describes the minimum requirements for the design, construction,
testing and delivery of station battery systems.

B. Related Documents

1. Work in this specification shall be coordinated with Specification MQ-SP-E-6000:

General Requirements – Electrical Equipment and Material.

2. See data sheet MQ-DS-E-6010: Datasheet for Station Battery and Charger for
additional system requirements.

3. See the Request for Quotation (RFQ) or Purchase Order (PO) for other documents
(one line diagrams, proposed layouts, nameplate lists, etc.) for other system
requirements.

1.2 References

The latest issues, amendments, and supplements to these documents shall apply unless otherwise
indicated.

Marafiq Engineering Specifications

MQ-DS-E-6010 Datasheet for Station Battery and Charger
MQ-SP-E-6000 General Requirements Electrical Equipment and Materials
MQ-SP-E-6001 Electrical Design

Institute of Electrical and Electronic Engineers (IEEE)

485 Sizing Large Lead Storage Batteries for Generating Stations for General Stations and
Substations
1115 Recommended Practice for Sizing Nickel Cadmium Batteries for Stationary Applications

National Electrical Manufacturer’s Association (NEMA)

PE-5 Utility Type Battery Chargers

Underwriters Laboratories (UL)

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 5 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

1236 Standard for Safety Battery Chargers

2.0 PRODUCTS

2.1 General

The system shall consist of a battery bank complete with intercell connectors and hardware, a
battery support, and a charger as described in the datasheets and documents.

2.2 Equipment

A. Battery Bank

1. Battery Construction

a. General

(1) The battery bank shall be designed for floating service under normal
operation with a periodic equalize charge from a connected battery charger.

(2) The cell containers and covers shall be molded of a material that is resistant
to heat, shock, and chemical attack. Cell containers shall be translucent or
transparent. The cell cover shall be permanently affixed to the container to
form a non-leaking seal. Covers shall be equipped with explosion resistant,
flame arresting vent caps.

(3) Battery case or posts shall be stamped with a date code identifying the
month and year of manufacture.

(4) Cell posts shall be sealed against creepage of electrolyte.

b. Vented Lead-Acid Battery

(1) The plate design shall be tubular or pasted plate lead-calcium alloy.

(2) Insulation between plates shall consist of microporous separators combined

with glass mat retainers to maintain proper spacing between positive and
negative plates and to permit free circulation of electrolyte.

(3) Electrolyte level lines shall be marked on all four sides of each container.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 6 of 11
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SPECIFICATION – STATION BATTERY AND CHARGER

c. Nickel-Cadmium Battery

(1) The battery cells shall be flat pocket plate type, consisting of powdered
active materials permanently contained in finely perforated nicked-plated
steel pockets set in steel frames, and have an alkaline electrolyte.

(2) The insulation between plates shall consist of edge and intermediate plastic
separators, to maintain correct spacing between positive and negative plates.

(3) Electrolyte level lines shall be marked on both post sides of each container
and shall be visible without obstruction when the batteries are installed in
the rack.

2. Battery Support

The battery support shall be as described below and indicated on the datasheets.

a. Battery racks shall be constructed of steel, coated with a material that resists the
corrosive effects of spilled electrolyte. Trays of corrosion resistant plastic shall
be provided under each rack to contain electrolyte spillage or leakage.

b. Whenever battery racks with covers are specified on the datasheets, the rack
described above shall include removable panels constructed of ¼ inch (6mm)
thick Plexiglass that shall enclose the entire rack. The cover assembly shall be
freestanding with a steel structure painted with corrosion resistant finish and
assembled with stainless steel hardware. It may be made up of more than one
section such that it will be easily removable after installation.

3. Battery Accessories

a. Intercell connectors and insulated intertier jumpers shall be supplied to provide

1/2 inch (13mm) spacing between cell and units for each battery bank. Intercell
connectors shall be lead plated copper for lead-acid batteries and cadmium
plated copper for nickel cadmium batteries. Stainless steel bolts, washers, and
nuts shall be provided for high torque low resistance terminations.

b. Each battery bank shall have the following maintenance accessories.

 Cell numbers and warning labels

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 7 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

 One cell lifting device

 One container and no-oxide grease
 One hydrometer with wall mounted holder.
 One thermometer with wall mounted holer.
 One filler bulb to adjust liquid levels of cells with wall mounted holder

B. Battery Charger

1. Construction

a. The charger shall be completely assembled and wired in a NEMA 1 enclosure

for rack, floor, or wall mounting as indicated on the datasheets. The enclosure
shall be arranged for front operation and maintenance. Removable side panels
may be provided, but rear access shall not be required.

b. The enclosure shall be constructed to permit conduit entrance at both the top and
bottom of the unit.

2. Design

a. The charger shall be solid state construction, filtered output, constant voltage
type. Rectification shall be achieved by the use of controlled ferroresonant,
magnetic amplifier, or silicon controlled rectifiers. The charger shall operate on
a 480 volt, three phase, high resistance grounded, 60 Hz system.

b. The charger shall be capable of limiting the output current to a maximum of 125
percent of its rating, under any condition of load demand.

c. Input and output power circuits shall have over-current protection, in the form of
thermal-magnetic type circuit breakers. Breakers shall be capable of being
manually operated with door closed.

d. Chargers of the same nominal ratings shall be capable of parallel operation.

e. The charger shall be capable of providing a voltage regulation of plus or minus

0.5 percent of the DC float voltage and plus or minus 1 percent of the
equalization voltage under any load condition, for plus or minus 10 percent
input voltage variation, and plus or minus 5 percent input frequency variation.

f. The maximum ripple shall be 2 percent rms when connected to battery.

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 8 of 11
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SPECIFICATION – STATION BATTERY AND CHARGER

g. The battery charger shall have an efficiency of 90 percent minimum at rated

load.

h. The battery charger shall be equipped with a timed "walk-in" circuit that causes
the charger to assume the load gradually after input voltage is applied.

i. The battery charger shall be capable of supplying rated load with the battery
disconnected.

j. The following controls, meters and indicating lights shall be supplied as

minimum;

 DC voltmeter with an accuracy of plus or minus 2 percent of full scale

 DC ammeter with an accuracy of plus or minus 2 percent of full scale
 Float voltage potentiometer
 Equalizing voltage potentiometer
 Float-equalizing selector switch
 LED indicating lights: power on, float charge, and equalize charge.

Digital meters are preferred.

k. The battery charger shall be equipped, as a minimum, with the following LED
alarm indicators on the front of the enclosure:

 AC input failure
 Charger failure
 Charger over temperature
 Overload shutdown
 Equalize charge mode
 Output breaker open
 High and Low DC voltage
 Low output voltage
 Cooling fan failure for force ventilated units
 Positive and Negative Ground fault

l. An alarm relay with two, dry type, form “C” contacts, wired to a terminal block
shall be provided for use as a common trouble output. Any system alarm shall
operate this relay.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 9 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

2.3 Design Criteria

A. Battery Sizing Criteria

Lead-acid batteries shall be sized in accordance with IEEE 485. The battery capacity
shall be determined utilizing the load profile, future growth factor, aging factor,
temperature correction factor, nominal voltage, and final discharge voltage as provided
on the datasheets and as described below:

1. A 1.25 (25 percent) aging factor shall be applied to the calculated capacity (AH
rating) to compensate for decreased battery capacity at the end of the battery's design
life.

2. A temperature correction factor shall be applied to the capacity of all battery types
based on the minimum temperature listed on the datasheets for temperatures below
77 degrees F (25 degrees C).

3. Unless otherwise specified on the datasheets, the final discharge voltage shall be
1.75 volts per cell.

B. Battery Charger Sizing Criteria

The battery charger shall be sized to charge a totally discharged battery in the period of
time indicated on the datasheets, while supplying the external load also indicated on the
datasheets. If required, the charger shall be derated for ambient temperature and altitude.

2.4 Finish

Manufacturer’s standard paint system shall be provided.

2.5 Identification and Tagging

Each major component and termination point shall be permanently identified by typed nameplates
located in a clearly visible location adjacent to the component or termination point. See
specification number MQ-SP-E-6000 for additional requirements.

2.6 Inspection and Tests

Equipment shall be inspected and tested in accordance with the Manufacturer’s standard procedure
and the following:
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 10 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

A. Routine Tests

1. Vendor shall perform standard routine tests on the battery and battery charger
system.

2. The batteries used in the test shall be similar to those to be shipped dry.

B. Special Tests

1. In addition to vendor’s standard routine tests, each battery and battery charger
assembly shall be tested in accordance with NEMA PE-5.

C. Witnessed Tests

1. Vendor shall notify the Company two (2) weeks prior to performing final tests. The
Company reserves the right to inspect the equipment, and to witness the tests at the
Manufacturer’s factory.

D. Test Reports

1. Certified test reports containing results of all tests on each unit shall be provided.

2. Charge and discharge characteristics of the batteries, impedance of each battery cell
and battery charger sizing calculations shall also be provided.

3. All test data shall be assembled and forwarded to the Company in accordance with
the purchase order.

4. If the tests show that certain requirements are not met, vendor shall make necessary
corrections to the equipment at no extra cost to ensure conformance to all
requirements before acceptance is made.

5. Vendor shall provide all testing equipment.

2.7 Preparation for Shipment

Preparation for shipment shall be in accordance with Manufacturer’s standard unless noted in the
documents. See specification MQ-SP-E-6000 for additional requirements.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification MQ-SP-E-6010
Project Name: Date: 01 Apr 2011
Contract Number: Page 11 of 11
Revision 1

SPECIFICATION – STATION BATTERY AND CHARGER

3.0 EXECUTION

Not applicable.

4.0 ATTACHMENTS

Not Applicable

End of Specification