Professional Documents
Culture Documents
for the
Bel Air Mining Project
APPROVAL
REVISION RECORD
Page Revision Description Date
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Battery Tripping Units
Specification
TABLE OF CONTENTS
1. INTRODUCTION.........................................................................................................................
2. SCOPE........................................................................................................................................
3. DUTY DESCRIPTION.................................................................................................................
4. DESIGN CRITERIA AND MATERIAL OF CONSTRUCTION.....................................................
5. MANUFACTURING AND CONSTRUCTION DETAILS..............................................................
6. QA REQUIREMENT....................................................................................................................
7. DRAWINGS AND DATA.............................................................................................................
8. PACKING AND MARKING.........................................................................................................
9. PAINTING AND PROTECTIVE COATING..................................................................................
10. PERFORMANCE AND GUARANTEE........................................................................................
11. REFERENCE STANDARDS AND SPECIFICATIONS................................................................
12. ANNEXURES............................................................................................................................ 10
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1. INTRODUCTION
1.1 This specification is for the supply of battery tripping units (BTU’s) for use with the MV
switchgear and data sheet covered in specification DRA-C8396-ECI-SPC-001
1.2 All equipment and services shall comply with the mandatory requirements of the Mines
Health and Safety Act 29 of 1996 and regulations (as amended). Particular reference
is made to Section 21 of the Act which, in terms of sub-clause 4, requires the
preparation and submission of a risk analysis before any equipment is delivered,
off-loaded or erected on site.
1.3 For general procedures and definitions see Annexure A1 of this specification.
2. SCOPE
2.1 GENERAL
The scope of work includes the furnishing of all labour, material and services for the
design, supply, manufacture, testing and inspection at works, delivery to site, offloading,
erection and commissioning and rectification of defects developing during the warranty
period for the BTU’s as specified below. The battery tripping units will be installed at
Adansi Gold’s Asanko Gold Mine new Gold Concentrator plant located near Kumasi in
Ghana’s Ashanti Region.
The work includes, but shall not be limited to the items listed below.
2.2.1 All work in 2.1 above.
2.2.2 Any special tools which may be required for the operation or maintenance
purposes including three (3) spare sets of each type of fuse for each unit
ordered.
2.2.3 Vendors are to detail at tender stage:
2.2.3.1 Lump sum price per battery tripping unit.
2.2.3.2 Rates for installation and commissioning (where required).
2.2.3.3 A list of recommended spares for a one year operating period and prices of same.
2.2.3.4 Rate for conducting a six (6) monthly inspection of battery tripping units at the place of
installation on the condition of batteries and chargers and submission of report to Mine
Resident Engineer following inspection.
3. DUTY DESCRIPTION
The units shall be suitable for operation in surface substations. Ambient conditions
within these substations would generally be as follows:
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Minimum -13ºC
Average 27ºC
Total DC amps
Type Qty Power (W) required (A)
MICOM relay 18 20 3.27
Building
emergency lighting 4 50 1.82
5.81
Battery capacity shall be a minimum of 10 amps hours at the 3 hour rate. In determining
this rating, due cognisance shall be taken of the variation in ambient temperatures
possible and the resulting variation in cell voltage. It is therefore required that the
specific amp hour rate shall be based on 80% of nominal cell capacity. Battery rating
shall be based on a final voltage per cell of 1,1 volts. Alcad type L16P or direct
equivalent are acceptable.
An alternative offer of “Vantage” type VN22L will also be considered.
The cells shall be charged by the float charge method, at a voltage to be recommended
by the supplier. Current limiting of the charger shall be included to give overall
recharging time from deep discharge condition of not more than 12 hours. Final charge
voltage shall be selected to give a minimum gassing level commensurate with a slight
positive pressure within the cell to reduce contact with outside air. Water loss should be
minimal at the selected voltage.
Due cognisance shall be taken of any sanding load specified in the data sheet attached.
In any case, the charger must have reserve capacity to supply 2 amps continuous
standing load during the entire charging period.
Cells are to remain maintenance free for many years. As an indication, the following
parameters are considered reasonable:
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4.7 ALARMS
The charger unit should provide a volt-free changeover contact wired to outgoing
terminals and local LED indication for the following conditions:
High voltage alarm: If boost charge is sustained for in excess of 20 hours, high
voltage alarm and battery disconnected from charger.
Low voltage/load test: At least once per day an automatic load test with low volt alarm
is to be cycled, with battery disconnected from charger during
test cycle.
Charger supply failed: Indicates failure of AC. supply to battery.
Earth fault alarm: Indicates condition of DC. insulation resistance decreasing
below 100 kOhm.
Provision shall be made for four (4) output circuits, each individually switched via a
suitable rated miniature DC. circuit breaker. A 100A 100V diode shall be connected in
series with the positive terminal of each output circuit.
5.1.1 Battery chargers shall be free-standing, complete with alarms and controls as detailed.
5.1.2 The battery shall be separately mounted and comprising vented nickel cadmium cells
with translucent, polypropylene containers.
5.1.3 Battery stand shall be a free standing, open stand for cells and manufactured from non-
corrosive stainless steel or rubberised wooden frames.
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Solid steel conductors shall be used for all cell interconnections using stainless steel
nuts and bolts and captive washers.
The stand shall be free standing, but of compact design. Adequate access shall permit
ease of monitoring all cell electrolyte levels and also of testing S.G. values with a
commercial hydrometer.
5.6 ERECTION
Where called upon to do so, (refer section ) the supplier shall erect the equipment in the
prescribed substation. This shall include termination of interconnecting cable between
charger and cells, intercell connectors and supply, installation and termination of a
suitably rated cable of minimum size 10mm² to the designated switchboard,
(interconnecting distance shall be assumed to be less than 30m, unless otherwise
stated). Cabling shall be of the low toxicity (flame retardant) type and otherwise shall
comply with SANS 1507 (blue stripe). Interconnecting cabling shall be steel wire
armoured and shall be fixed in place using galvanised saddles at 800mm intervals. The
power supply to the battery tripping unit will be installed by others but shall be terminated
by the Vendor.
5.7 COMMISSIONING
Where called for the Vendor shall commission the battery tripping unit on site. This shall
include checking terminations, filling the battery with electrolyte and tuning and setting of
all charging functions to suit local ambient conditions and standing load requirements.
6. QA REQUIREMENT
Following installation and commissioning, the following tests / checks shall be carried
out:
6.2.1 Measurement of float voltage at full charge.
6.2.2 Measurement of float current at full charge.
6.2.3 Measurement of boost charge rate.
6.2.4 A one-hour discharge test at C3 rated current and measurement of final output voltage.
A certificate detailing the results of the above tests shall be submitted to the Engineer
(see 7.1.2).
7.1.1 Drawing and documentation shall be to DRA / Client standard, see Annexure A3 for
more detail.
7.1.2 Ten certificates are to be submitted after the execution of the type and routine testing.
10.1.1 The performance of the items supplied in terms of this specification, as defined by the
order, shall be warranted by the Vendor/Contractor and, if specified, be tested in
accordance therewith.
10.1.2 The vendor/contractor shall not be specifically required to conduct a performance test on
site.
10.1.3 A minimum guarantee period of 12 months is required.
11.1.1 All equipment supplied shall comply with the requirements of the standards:
BS 6260 - Nickel Cadmium Open Type Prismatic Cells
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12. ANNEXURES
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ANNEXURE No. A1
VENDOR Q.A. AND DOCUMENT REQUIREMENT LIST
QA CLASSIFICATION A1
TABLE OF CONTENTS
REQUIRED
SECTION DESCRIPTION WHEN REQUIRED
(YES OR NO )
DRAWINGS & DESIGN CALCULATIONS
DESIGN GA DRAWINGS
(2 SETS OF EACH) DETAIL DRAWINGS
AS BUILT DRAWINGS
BROCHURES
SCHEMATIC DIAGRAMS (ELECT)
RISK ASSESSMENT BY VENDOR YES ORDER + 2 WEEKS
DATA SHEETS (ELECTRICAL) YES DATA BOOK
DATA SHEETS (MECHANICAL) YES DATA BOOK
DESIGN CRITERIA
MATERIAL
CERTIFICATES
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ANNEXURE No. A2
TITLE: PAINTING AND PROTECTIVE COATING
Paint
Host Thickness
System Preparation Primer Intermediate Finishing
Material µm
No.
Abrasive blast to SA Inorganic Epoxy
WS 1 Mild Steel Epoxy 200
2.5 zinc silicate Enamel
Abrasive blast to SA Epoxy
WS 2 Mild Steel Epoxy Epoxy 200
2.5 Enamel
Acid pickle
plus 7 stage zinc Epoxy
WS 3 Mild Steel Epoxy Epoxy 150
phosphate pre– Enamel
treatment
Paint Total
Primer Finishing Coat
System Host Material Preparation Thickness
(70µm) (70µm)
No. µm
Acid pickle plus 7 stage
EPC 1 Mild Steel Epoxy Polyester 140
phosphate pre–treatment
Pre-galvanised
EPC 2 Surface wax removal Epoxy Epoxy 140
sheet (Z450)
1.2.1.3 For each paint application, three test panels must be prepared
(approximately 200mm x 200mm) of the same material as the
actual job. They must be coated in exactly the same manner as
the actual job and submitted to the powder manufacturer for
testing on completion.
1.4 Galvanising
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TES:
1. With the exception of the use of Type 304L stainless steels in Type 5 Plant Severe-Sulphuric Acid, the preferred corrosion protection
systems are applied onto cold rolled mild steel plate with a thickness of 1.6 or 2.0mm.
2. For each type of conditions, two or three corrosion protection systems have been given in descending order of expected performance in
the given conditions. The particular location of the switchgears and/or enclosures, e.g. whether located in dust-free or air conditioned
rooms, or whether located in areas outside the specific conditions, must also be taken into account. For example, System 3 may be
used with a higher expected performance if the equipment is located in an air-conditioned room within the plant or mine environment.
3. The details of the system given in each case are generic. Only approved materials and applicators/vendors should be used and should
be asked to submit formal detailed specifications including the following:
Approved brands or types of products
Application and curing details
Quality assurance procedures, including a Quality Control Plan (QCP) and inspection/testing routines
4. The performance estimates given are based on previous experience and judgement in terms of the various types of conditions. As there
are many different factors that influence performance, e.g. maintenance, mechanical damage, operational procedures, etc., these
estimates should only be used as guidelines when the different options, and their cost implications, are being considered.
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Key: WS 2/10
Life expectancy
Paint System
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ANNEXURE A3
TITLE: SPECIFIC REQUIREMENTS
Tenderers shall complete this Data Sheet and submit it at the time of tendering.
Double above
2. Electrolyte capacity container
value
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ANNEXURE A3 (continued)
TITLE: SPECIFIC REQUIREMENTS
Project Supplier Offer
Feature
requirement or Compliance
13. Recharge time to 80% from fully discharge …... hours
…… mm²
19. Minimum conductor size of switchboard 10 mm² (based on 30m
run)
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