SPEC. No.

FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 1 of 12

FUNCTIONAL
SPECIFICATION
FOR
BATTERY & BATTERY CHARGER

PREPARED / REVIEWED APPROVED BY TOTAL NO. OF DATE REV.

REVISED BY PAGES
BY

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004A ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 2 of 12

CONTENTS

1. SCOPE................................................................................................................................. 3
2. CODES & STANDARDS ................................................................................................ 3
3. SITE CONDITIONS......................................................................................................... 3
4. SCOPE OF SUPPLY.......................................................................................................... 3
5. TECHNICAL REQUIREMENT...................................................................................... 4
5.1. GENERAL................................................................................................................. 4
5.2. SAFETY ..................................................................................................................... 4
5.3. BATTERY CHARGER ............................................................................................ 4
5.4. BATTERY.................................................................................................................. 7
5.4.1. BATTERY BANK ................................................................................................ 7
5.4.2. BATTERY RACKS .............................................................................................. 8
5.4.3. CONNECTORS ................................................................................................... 8
5.4.4. TOOL KIT AND BATTERY ACCESSORIES................................................ 8
6. TESTING AND INSPECTION ...................................................................................... 9
7. SPARES............................................................................................................................... 9
8. WARRANTY.................................................................................................................... 10
9. VENDOR DATA REQUIREMENTS .......................................................................... 10
10. CONFLICT.................................................................................................................. 11
11. CERTIFICATION ...................................................................................................... 11
12. PACKING & TRANSPORTATION....................................................................... 12
13. ATTACHMENTS....................................................................................................... 12

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 3 of 12

1. SCOPE

This specification defines the requirement of the battery and battery charger system
required to be installed on offshore platforms. Batteries shall meet the requirements
of loads listed in attached data sheet.

2. CODES & STANDARDS

2.1. All batteries, battery chargers and their accessories supplied shall comply with
the requirements of the latest revisions of the relevant standards of :

ISI INDIAN STANDARDS INSTITUTION

IEC INTERNATIONAL ELECTRO-TECHNICAL
COMMISSION
BSI BRITISH STANDARDS INSTITUTION
NEMA NATIONAL ELECTRICAL MANUFACTURERS
ASSOCIATION
NEC U.S. NATIONAL ELECTRICAL CODE
IEEE INSTITUTE OF ELECTRICAL & ELECTRONICS
ENGINEERS
API AMERICAN PETROLEUM INSTITUTE

2.2. Any other recognized international codes or standards may be followed in lieu
of above with prior approval of the Company.

3. SITE CONDITIONS

All the equipments shall be designed and tropicalised to withstand the site
conditions as specified in General Design Criteria enclosed in the bid package.

4. SCOPE OF SUPPLY

The scope of supply includes:

4.1. Nickel- Cadmium battery bank, racks and accessories.

4.2. Battery charger panel
4.3. Ni-Cr plated double compression type brass cable glands and tinned copper
lugs.

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 4 of 12

4.4. Any other components or accessories, if not mentioned specifically, but

considered essential to make the system complete for safe and reliable
operation shall be included in the contractor’s scope of supply.

5. TECHNICAL REQUIREMENT

5.1. GENERAL

5.1.1. The battery charger, battery and specified auxiliary components shall be
the products of firms regularly engaged in the manufacture of these items
and shall meet the requirements of this specification.

5.1.2. All materials and parts comprising part of the equipment specified herein
shall be new and unused, of current manufacture, of the highest grade
and free from all defects and imperfections that could adversely affect
the performance of the system.

5.2. SAFETY

It is the intent of the purchaser that operational hazards be reduced to

minimum. The vendor shall use good engineering judgment in providing
equipment to complete an installation that could perform the required function
without compromising on safety. All controls shall operate in fail-safe-mode.

5.3. BATTERY CHARGER

5.3.1. Two chargers shall serve each battery assembly. Each battery assembly
shall comprise of two Nos. battery packs each rated 50% by amp. hour
capacity and suitable for full voltage level.

5.3.2. Normal operation will require that the battery assembly will be float
charged by both chargers while feeding the D.C. loads, thus working in
parallel to each other. In case of failure of either of the chargers, the
other will float charge the battery assembly while supplying the
complete D.C. load. The faulty charger shall get disconnected from the
healthy system automatically. In case of A.C. Mains failure, the battery
assembly shall supply the load automatically without any break and shall
stop feeding the load as soon as AC mains supply is restored.

5.3.3. These chargers shall also boost charge ½ of the battery assembly as and
when required. The charging will be off-line i.e. while disconnected

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 5 of 12

from the charger supplying the D.C. load and float charging the
remaining ½ of the battery assembly. It shall be possible to boost charge
each of the battery section in either “manual” or “auto” mode. In auto-
mode, boost charging shall be automatically initiated when the battery
charging current demand increases. In this situation, the rectifier shall go
into current limit. If this situation persists beyond a preset time, the
rectifier shall be switched on to boost charging. The system shall return
to float charging after the preset time, or when the auto/manual selector
switch is turned to manual position and float/boost selector switch is
pushed into float position. In manual mode, boost charging shall take
place and continue for the preset time. The system shall return to float
charging after the pre-set time, or if float/boost selector switch is pushed
back to float position.

5.3.4. The design of each of the chargers shall be identical and rating of either
charger shall be selected for the worst case of duty out of the following:

5.3.4.1. Off line boost rate charging of ½ of the battery assembly from a
discharge state to fully charged state in 10 hrs.
5.3.4.2. On line float charging of the complete battery assembly (both ½
sections connected in parallel) plus supplying the complete DC
load.

5.3.5. Battery charger (s) shall be sized based on the nominal rated capacity of
the battery. Complete battery charger system including rectifier, battery,
and static switches, etc. shall have 10% spare capacity for future load
growth.

5.3.6. The battery chargers shall conform to the requirements specified in the
data sheets attached. The battery chargers offered shall be of solid/state
design. Design features must include electronic compensation to limit
regulation effects due to either line voltage variation for load and
temperature change. A 30 millivolt filtering shall be provided in chargers
for batteries of 48 V or less and 100 millivolt filtering shall be provided
in chargers for batteries above 48 V. Battery charger shall be of the
constant voltage with current limit type with protection against reverse
battery connections and open circuit on the output. The battery charger
shall be provided with Audio Visual alarms as per the data sheet. The
chargers shall be provided with facilities for load sharing, load balancing
and for paralleling of the incoming charger with the charger already on
load, without any system disturbance. Blocking diode protection and/or

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 6 of 12

current limiting protection shall be provided for all electronic circuits. A

battery voltage sensor shall be included to prevent overcharging of
batteries. The battery charger shall have surge suppression resistors both
on AC & DC sides. Wherever required, silicon dropper diodes shall be
provided in the battery. The battery charger will have surge suppressions
resistors on both AC&DC sides. Wherever required silicon droppers
shall be provided in the battery chargers to meet the narrow voltage
band. To prevent both batteries being boost charged simultaneously
further interlock shall ensure that before switching one charger to the
boost position, the second charger shall be in its float charge condition
and shall be supplying power to the DC output. Timer (0-24 hours) for
automatic changeover of the modes from boost to float shall be provided
with bypass features. The interlocking device shall inhibit one charger
from being switched into boost charging when,

5.3.6.1. The other charger is being switched into boost charging either
manually or by the automatic device during normal operation.
5.3.6.2. The battery circuit breaker of the other system is tripped.

5.3.7. Battery charger shall be mounted in an enclosure with minimum degree

of protection, IP-51 suitable for use in a pressurized building and also
capable of with standing the tropical marine environment of the site.
Painting shall be done as per General Specification – Protective Coatings
(Spec. No. 2005). Enclosures shall have front access and shall be
suitable for floor mounting.

5.3.8. Each rectifier unit shall have an incoming AC circuit breaker and
outgoing DC circuit breaker feeding DC bus. The bus shall be
adequately sized and rated for the conditions specified. The bus joins
shall be bolted. Bus insulation shall be flame retardant. The incoming
DC breakers to DC bus shall have shunt trip coils. The main DC bus
shall feed the DC Distribution board through circuit breaker. The circuit
breakers shall be moulded case type and suitable for prospective fault
levels. AC incoming side of bus chamber and outgoing DC circuits shall
be segregated from one another. Necessary termination accessories shall
be included in the contractor’s scope of supply. Cable entry shall be from
bottom of panel. The complete panel shall be suitable for operation and
maintenance from front only.

5.3.9. 2.5 mm2 PVC insulated copper wire, 600 volt rated, shall be used for
control wiring and 0.75 mm2 PVC insulated copper wire shall be used

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 7 of 12

for electronic circuitry. Wiring to door mounted devices particularly,

shall be stranded. Wire lugs shall be crimping type. Bundles of wires
shall be routed neatly in vertical or horizontal planes. Individual wires of
bundles shall be secured with PVC wire ties, cable lacing or by enclosing
in PVC wire trays. All components and all insulation shall be treated to
prevent fungus growth. All terminal blocks shall be rated 16 amperes
(minimum) at 600 volts. All terminal blocks shall have white PVC
marking strip throughout the length of the block. Each block shall have
10% spare terminals. All wiring shall be identified by permanent slip-on
or clip-on marking sleeves on each terminating wire in addition to the
mark on the block.

5.3.10. Nameplates shall be 3-ply, white-black-white, 2 colour, and laminated

plastic. Lettering shall have 5mm minimum height, and edges shall be
bevelled at 450.

5.3.11. A space heater along with adjustable setting thermostat shall be provided
inside the battery charger cabinet for driving out moisture contents. The
circuit shall be connected through MCB and separate terminals for
connecting A.C. supply for space heater “ON” condition.

5.4. BATTERY

5.4.1. BATTERY BANK

The batteries shall be of Ni-Cd cells of nominal voltage specified in the

Data sheet. The battery shall be supplied with high impact translucent
plastic enclosures for visual electrolyte inspection and shall have flame
arresting recombination vent. Battery bank capacity in Ah shall be
adequate for the specified load and site conditions. Depth of discharge
(DOD) of 100% and ageing factor of 0.8 shall be taken into
consideration while sizing. The end cell-voltage after discharge shall be
limited to 1.1 volt per cell. The battery shall be such that there will be
minimum water loss during charging due to evaporation. The discharge
performance of the battery shall be compatible with the envisaged load
cycle. Batteries shall be suitable to withstand at least 1600
charge/discharge cycles involving 70% DOD. Each battery bank shall
have 10% spare capacity for future load growth.

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 8 of 12

5.4.2. BATTERY RACKS

Battery racks shall be PVC lined steel frame rack with cells installed on
PVC lined trays. The battery rack shall be complete with all support and
tie down equipment. Arrangement requiring minimum space shall be
provided. The rack assembly once assembled shall be shock and
earthquake proof to Zone IV as per IS: 1893 and suitable for installation
on offshore structure. The rack design shall be selected considering
following factors.
- Space on the offshore platform is limited.
-
Lower weight is preferred.
-
Ease of maintenance of mounted cells.
(The arrangement shall be such that minimum space is required for
installation).

5.4.3. CONNECTORS

Suitable tinned copper links for intercell and inter-row connectors with
PVC sleeving and end take-offs shall be provided with clamping
terminations. Care shall be taken to overcome bimetallic corrosion. The
terminal connection shall be anti-loosening against vibration. These shall
be suitable for the salt laden marine environment. If more than one
battery banks are proposed to achieve required loads or voltages, cables
for interconnection shall be included in vendor’s scope of supply.

5.4.4. TOOL KIT AND BATTERY ACCESSORIES

Vendor shall furnish a lockable steel box complete with accessories as

mentioned below:

- Two (2) Hydrometers for electrolyte specific gravity readings.

-
Assorted connectors , lugs, nuts, and vents,
-
One (1) Cell testing voltmeter.
-
Two (2) Pairs rubber hand –gloves.
-
Two (2) Aprons.
-
Six (6) Spanner nut wrenches.
-
One (1) Electrolyte pouring funnel.
-
Two (2) Thermometers.
-
Four (4) Level testers.
-
One (1) No. spare Cell

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 9 of 12

-
Acid/ Alkali resistant jugs and funnels, eye protection devices
(goggles).
Vendor shall also furnish the required quantity of electrolyte, plus 10%
extra in non-returnable containers. Warning labels and instruction
manuals for operation, maintenance and installations shall be included
in vendor’s scope of supply.
6. TESTING AND INSPECTION

All tests shall be carried out as per relevant standards at vendor’s works. In case the
actual battery to be supplied is not available, tests may be conducted using identical
alternate battery supply. Testing and inspection of battery/charger system shall
include but not necessarily be limited to the following.

6.1. A visual inspection shall be made to ensure that good workmanship and
practices were maintained throughout fabrication and assembly.
6.2. A quantitative check shall be made to ensure that all items in specified
quantities are present according to the purchase specifications and packing list.
6.3. A functional test shall be conducted with all controls and alarms for correct
setting and operation.
6.4. Capacity and load cycle test for battery.
6.5. Testing and calibration of all indicating instruments.
6.6. Insulation resistance test of all wiring
6.7. Burn out test on all equipment collectively as one system for 100 hours.
6.8. If the tests show that certain requirements of this specification are not met,
vendor shall make necessary corrections to the equipment before offering it for
acceptance so that it satisfies all the requirements.
6.9. Company reserves the right to have a representative to witness tests performed
and request corrective action, wherever necessary.
6.10. Vendor shall notify Company twenty days prior to testing. Vendor shall
furnish test date and location to Company for decision on exercising its right
to witness the test.

7. SPARES

7.1. Vendor shall provide spare parts needed for start-up. In addition, vendor shall
also furnish a separate priced list of recommended spares for two (2) of normal
operation and maintenance. Recommended spares shall take into account the
related factors of equipment reliability, effect of equipment downtime upon
production, safety and cost of parts and availability of equipment service
facilities.

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 10 of 12

7.2. All spares furnished by vendor shall be wrapped and packaged so that they will
be preserved in original as new condition under the normal conditions of
storage prevailing in India and shall be properly tagged to facilitate future and
coded identification as to intended equipment usage will be facilitated. They
shall be packaged separately, clearly marked as “Spare Parts” and shipped
along with the main equipment. Packing lists shall be furnished so that the parts
can be handled without uncrating, if desired.

8. WARRANTY

Vendor shall have final and total responsibility for the design and performance of all
the batteries, battery chargers and their accessories supplied under this specification.
The equipment and the system shall be guaranteed for trouble-free operation for a
period of 12 months from the date of commissioning or 18 months from the date of
arrival at site whichever is earlier. Any defects discovered during this period shall
be rectified free of charge. These provisions shall, in no way, effect the overall
contractual obligations of the turn key contractor as stipulated in ‘General
Specifications: Definitions’. (Spec. No. 1050)

9. VENDOR DATA REQUIREMENTS

Vendor shall furnish the following data/information related to the battery sets and
chargers.

9.1. Arrangements drawings with outline dimensions including clearance

requirements.

9.2. Electrical details

- Equipments details
- Mounting details
- Completed data sheet
- Battery and charger sizing calculations
- Calculation for selection of dropper diodes on load terminals

9.3. Electrical wiring

- Schematic diagrams
- Single line diagram

9.4. Electrical reference material

9.4.1. General Description

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 11 of 12

9.4.2. Performance data, catalogues, brochures and certified test reports.

9.4.3. Part list & Bill of materials
Bill of materials should as minimum, contain following
information/details in respect of each component of the battery charger-
(a) Name of component
(b) Rating
(c) Type/Model Reference
(d) Quantity installed
(e) Part No.
(f) Manufacturer’s Name and address.

9.4.4. Circuit breaker operation curves

9.4.5. Recommended spare parts with prices
9.4.6. Code certificates
9.4.7. Operating and maintenance instructions

10. CONFLICT

In the event of conflict between this specification and other documents listed herein,
the following order of priority shall govern:-

i) Basic Bid Work

ii) Design criteria, drawings and data sheet (whichever applicable).
iii) This specification
iv) General Specifications
v) Codes and Standards

11. CERTIFICATION

All the offered batteries, battery chargers and their accessories or those of similar
design and construction features manufactured by same vendor:

• shall have been type tested by an authority approved by the Company.

• shall have been in continuous satisfactory service in off-shore for a
minimum period of two years.
• shall be having current certification/approval/listing by an approved agency
or UL or FM.

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003
 SPEC. No. FS 4023
OFFSHORE FUNCTIONAL
DESIGN SPECIFICATION FOR Rev. No. 1
BATTERY & BATTERY
SECTION CHARGER Discipline Elect
Page: 12 of 12

12. PACKING & TRANSPORTATION

The offered batteries, battery chargers along with their accessories, shall be shipped
to site packed in wooden crates. They shall be wrapped with polythene sheets,
before being placed in the crates to prevent damage to finish. Crates shall have skid
bottom for handling.

13. ATTACHMENTS

The following documents shall form part of this specification.

1050 DEFINITIONS
1060 VENDOR DATA REQUIREMENTS
2005 PROTECTIVE COATING
DS 4023 DATA SHEET

Format No Ref. Proc. No Issue No Rev No Rev. Date

ODS/SOF/004B ODS/SOP/008 to 015 01 01 15/10/2003