I

BSNL BHARAT SANCHAR NIGAM LIMITET)

QA & INSPECTION CIRCLE
Bulk QA Test Schedule For Lithium lon Battery
For BSNL Tender NO. MM/LWE/GBTJaaSPn-73712022 Dsted 11-08-2022

No. CCM (OA&n /TSEC (CGl/TBt SchedulB GAT/OA)/125n0-2U?2 Drted 03.0t.2023

Ref: 1. TEC/GR/DOLIB-001/0I.MAR.20I6 amendment I d*ed22.12.2021

2. TEC GLNo.: TEC IGLE A/LlB,80ll0lllt.1r'.-20
I. Generrl Informrtiotr

a) BSNL QA ofler no
b) Name of the Manufacturer
c) tA reference & ValiditY
d) TSE Certificate No.
e) Puchase Order No.
0 Consignee
g) Modules Sl. No
h) Battery Confi guration
i) Capacity
j) Date ofcommencement ofBPC
k) Date of Completion ofBPC

Il. General Verifi crtion:

A) Ofier Lettcr
and theil apFoval ststus fol the purpose of
The offer letter shall indicate the souces of raw materials
one week before the delivery
traceability in case of failures The batteries shall be offered minimum
date. The offer letter shall invariably contain the following:
a) Module Production batch No and SLNo in that batch'
sets'
b) Rac!/cabinet with serial nurnben mapped to the battery
atong with OCV of modules'
c) ln-house test results in respect of Modules/ Batteries

B) Geoeral Checks
& Rack/cabinet procurcd
a) lnvoices and Bill of entry for the basic cell and invoices of BMS
cross verify with respect to
fiom various sub vendors shall be obtained from manufacturer,
TSEC report and recorded.

b) Availability of factory test records/ln-house test results as per the requirement'

per BoM in the
c) veriflcation of copy of MoU with basic cell manufacturer & its validity as
TSEC & BIS certificate ofbasic cell and its validity'
BMS PCB HW (Part
d) verificatior of copy of MOU with BMS PCB supplier' its validity and
number)/Sw /protocols as per BoM in the TSEC'
its validity as per
e) verification of copy of MOU with Chassis of Module/Rack manufacturer'
BoM in the TSEC
0 Verification of stacking arrangements as p€r TSEC'
chassis as per TEC GR
g) Verification of Markings on the Module enclosure & RacVcabinet
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IBSNL BHARAT SANCHAR NI(;AM LIMITED
QA & INSPECTION CIRCLE
Bulk QA Test Schedule For Lithium lon Battery
For BSNL Tender NO. MM/LWE/(;BT-IaaSPll-737/2022 Dated t4-052022

h) Name ofthe compary as "BSNL" and,,BSNL logo,'in colour shall be screen printed on the Modules
as per TEC GR.
i) Checl the spares and accessories offer€d along with the equipment as per TSEC/Tender.

III. DCL Checks

The following check sha.ll be carried out as per the SpecificatioDs requireme[t.
a. Physical verification & Dimensional checking of celUModule covers, Rack structure, nuts,
bolts & washers as per BoM and as per drawings.
b. Physical verification of connecton & Bus bars (+ve & -ve) and connecting wires to the bus
bar from the modules (for C/2 rare ofcharge & discharge) as per drawings.
c. Packing verification- Packing procedure, accessories as per BOM along with two numbers
of
Instauctional manuals.

IV. Bulk Acceptatrce Telts:

Bulk acceptance testing would be carried out as per Anrexure.I Enclosed
Lot Size: Maximum of 50 sets of battery banks per offer (i.e. 5OXg=400 Modules
for gO0 AH
Battery)

The samples would be picked up randomly as mentioned

below.

Dcscription Sampling Procedure/plan

one Battery Bank set m@
Battery Bark numbers of modules out of 25 offered sets (i.e. 200 numbers
of
System testing. modules for 800AH Battery) and be tested with one
of the offered
lack/cabinet.
The sampling plan@
II attached in Annexure-II.
The sampling plan wouldE as per IS-2500 General
lnspection
level-l attachcd in Annexure-II.

V. Surveillance Tests:
The following tests shall be carried out at least
once jn THREE motrths on each module.
Oprimization (Vottage between 3.0 V to 3.5V)
.i.
ii. Transient Response Test.
iii. Monitodng funcrionality.
iv. Thermal runway on cell,
v. Protection &-Alarm Tests as per TEC GR & TSTp
CL no.6.5. (Over rempeBrure protection as
per GR GL No.: TEC tGLn NttB-BOt/Ot/rUL_20.)

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BSNL BHARAT SANCHAR NIGAM LIMITED
AA & INSPECTION CIRCLE
Bulk QA Test Schedule For Lithium Ion Battery
For BSNL Tender NO, MM/LWE/GBT-latSPn-131n022 Dated 14-0&2022

VI. Guidelines for Bulk OA testirq:

a) Whenever the manufactuer offers Lithium-ion battery for Bulk QA testing in the stardard
offering memo (as per format QA-01) along with the in-house test results (as per format
QA-02), $e inspecting / testing officer has to enter the offering memo in the QA soft on
the date of receipt of offer.
b) The Offered lot of battery is to be physically verified for serial number ofmodules & in
sequential order as per the offering memo.
c) The sample modules are to be selected after analyzing intemal test results & OCVS
recorded batch wise as per IS 2500 or latest issue.
d) OC Voltages ofthe offered Modules (should be recorded in format QA-03): Shall be
rest cted to 3.30V to 3.45V (49.50V-51.75V) this is to ensue proper charging during
Float.
e) The sample Modules selected for testing are to be verified for dimensions (Length,
Width, Heighl and Weight) and arc to be compared with TSEC values and the
observations are to be recorded as pei the Format No. OA - 04
0 The Connectors (Inner Cell & Terminal Connecto!) are to be verified as per Format No'
OA -{5 &
for Lenglh, Width Thickness and are to be compared with TSEC
observations.
g) The readings during C,2 rate ofDischarge on sample modules are to be recorded'
h) The discharge test sheets are to be duly signed by the lesling officer with date along with
seal.
i) The DCL check repon ar€ to be as per format No. OA - 06
j) The packing SIip is to be verified and compared with TSEC packing slip .Minimum of2
packing boies are to bc opened and verified. Any modifications/additions/deletions
should have approval ofDGM (QA) FomatNo. OA 10.
k) AH and WH efficiency as p€r Format No. OA - 08A- 08B. & 08C
D Transient Response test as p€r Format No. q!:109.
m) Surveillance tests shall be conducted once in 3 months.
n) The records of Purchase order, offering memos, factory in-house test results and bulk
QA test results are to be maintained.
o) The Raw material tests shall be conducted either at in-house lab or at a recognized
extemal laboratory at least once in THREE months as per respective TEC specification

-M" sW-

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BSNL BHARAT SANCHAR NIGAM LIMITED
QA & INSPECTION CIRCLE
Bulk QA Test Schedule For Lithium Ion Battery
Ior BSNL Teader NO. MWLWE/G BT-IaaSP n-131/2022 D^ted 14-08-2022

Annexure-l
Bulk AcccDtancc Tests
l. Battery Bank Tcst:
TEC CR / TSTP
st. Clause No.
Tcst Description

Voltases durirg Discharqine

Discharging rate (C/5) as per TEC GR CL No: 3.4 (c).
I 1.4(c)
The communication between BMSS ro CBMS has to be verified. In case
of failure ofCBMS, Individual modules should continue to function and
power to be supplied to the load without break.

2. Ilodule Tc\t,r:

TtrC (;R / TSTP

sl. Cl No. Test Description
No.
Cell Mrtchinq,
The difference between the cell voltages in the cell module srring, wirh rhe
l 3.t l highest & lowest open circuit volr.ge shall be less than 0.05V under fully
recharged condirion. (Appr. lhr to 3hr).

Cell voltages: 3.30V to 3.45V

Module Voltages: 49.50V lo 51.75Y
Module Capacitv at C/2 @ 25oC as shall be verified.
2 4.3
On discharge of banery module, the capacity shall not be less than 97% of
rated capacity.

Amoere Hour (AH) Emciencv: Shall b€ better than 95y.

3 3.8 (Discharge ) Charge ) Discharge)
AH Efficiency: (2nd Discharge /Charge) x l0O

Wrtt llour fWHt Emciencv: Shall be better than 909/0

1 3.9 (Discharge ) Charge ) Dischalge)
WH Efficiency: (2nd Discharge Wh / Charge Wh) x t00

WH Efficiency: (2nd Discharge Avg Value / Charge Av8 Value) x

Ah Efficiency.
5 6,I Data Disolgv Accuracv: (Shall be bett€r-than)
Voltage (0.5%), Current (2%) & Temperarure (2%)
6 6.) !4glt!qt!g rulslglr Celt voltage, Nain., vax Voltage, 'r'oGE diferen.c.
Temperature, Module Vohage, Module Current, SOC.SOH etc.
7 6.1 Cell balancing, Log book function, authenticationinalaentif""tion.

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BSNL BHARAT SANCHAR NIGAM LIMITf,D
QA & INSPECTION CIRCLE
Bulk QA Test Schedule For Lithium lon Battery
For BSNL Tender NO. MM/LW UGBT-Ia'SP(-131n022 Dsted 14-08-2022

8 I 6.5.6 CeU Unbalance (All the Cell voltage betwe€n 3.0 to 3.5V & BMS will
calculate mean value, any cell voltage is higheror lower than 200mV from
mean value then declare cell unbalance

J. Rack-/Cabinet Testl
Sl. No. Tesi Description
I VerificatioD of IP 55 certificate.
2 Forced air cooling arrangement.
l Dimensions as per drawing ofTSEC model.
.l Thickness ofthe metal sheet as per TsEc/rhanufacturer sp€c.
) Cable entry arrangement.

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IBSNL BHARAT SANCHAR NIGAM LIMITET)
QA & INSPECTION CIRCLE
Bulk QA Test Schedule For Lithium lon Battery
Fo r RSNL Tender NO. MM/LWE/G BTJ aaSP lI-131 12022 Dated 14-0a-2022

Annexure-II
Samoline as oer lS 2500
T.U. I - Smd..t . cod. r.ll rr (s.. rO.! .nd tO.2)

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Page 6 of7

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I
BSNL BHARAT SANCHAR NIGAM LIMITED
QA & INSPECTION CIRCLE
Bulk QA Test Schedule For Lithium lon Battery
For BSNL TeDder NO. MM/LWf,/GBT-IaaSPn-73712tr22 Dated l1-0V2022

Acceptarce Ouditv level (AOL)l

AQL as mentioned below may be followed as per lS 2500.
a) No Critical defects are allowed.
b) For Major defects AQL 1.5% may b€ followed as per IS2500
c) For minor defects AQL 2.5% may be followed as per IS 2500

Cl$sificstiotr of Defech rs Criticrl. Mrior trd Minor.

I ) Critical Defects:
a) Charging and Discharging (As p€r TEC GR C1.No.3.3, 3.4( c)
b) Module Capacity at Cl2 @25oC ( As WITEC GR Cl. No. 4.3)
c) Ampere Hour (AlI) Efficiency, watt Hour (wIO Efficiency (As per TEC GR Cl. No 3.8 &
3.9)
d) Cell balancing, Log book function, authentication and idenrification (As per TEC GR Cl. No
6.3)
e) Cell Unbalance (As per TEC GR Cl. No 6.5.6)
0 The ditrerence between the cell voltages (As per TEC GR CI. No 3.1l)
2) Major Defects:
a) Monitoring Function (As per TEC GR Cl. No 6.2)
3) Minor defects:
a) Data Display Accuracy (As per TEC GR Cl. No.6. I )

Nele:
I ) Battcry Bank resting: In case of failure of set(s) during C/5 discharge test, for each failed set 2
sets (including the failed one) shall be tested again and both the sets shall pass. If not, the entire
lot shall be rejected.
2) Module Testing: ln case of failure ofmodule(s) during C/2 discharge test, the failed module(s)
and cqual number of other modules together shall b€ tested. All modules shall pass, if not the
entire lot shall be rejected.
3) Major and minor defects (ifwithin the AQL limit) shall be rcpaired/corrected/ replaced as the
case may be before dispalch.

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