EDITORIAL REVISION

April 2001

Process Industry Practices

Electrical

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations
USE WITH L-19M

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin, Texas
78705. PIP member companies and subscribers may copy this Practice for their
internal use. Changes, overlays, addenda, or modifications of any kind are not
permitted within any PIP Practice without the express written authorization of
PIP.
PRINTING HISTORY
November 1999
Issued
April 2001
Editorial Revision
Not printed with State funds

April 2001

Process Industry Practices

Electrical

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations
Table of Contents
1. Introduction .................................. 2

5. Inspection and Testing ............... 7

1.1 Purpose ............................................. 2

1.2 Scope................................................. 2

6. Shipping ....................................... 8

2. References ................................... 2

7. Documentation ............................ 7

2.1 Process Industry Practices ................ 2

2.2 Industry Codes and Standards .......... 2
2.3 Conflict Resolution............................. 2

7.1 Documentation Content ..................... 8

7.2 Drawing and Data Requirements....... 9

3. Definitions .................................... 3
4. Design........................................... 3
4.1
4.2
4.3
4.4.
4.5.

General .............................................. 3
Cells ................................................... 5
Battery Racks .................................... 6
Accessories ....................................... 7
Markings ............................................ 7

Process Industry Practices

Page 1 of 9

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

1.

April 2001

Introduction
1.1

Purpose
This Practice provides the requirements for the purchase of vented lead-acid batteries
including design, inspection, testing, shipment, and documentation for application in
process industries.

1.2

Scope
This Practice and Data Sheet cover the minimum requirements for vented lead-acid
batteries. It includes requirements for design, inspection, testing, shipment, and
documentation for vented lead-acid batteries for application in electrical stations in
indoor, non-classified areas. For requirements for vented lead-acid batteries for
uninterruptible power supplies (UPS), refer to PIP ELSAP15.

2.

References
Applicable requirements in the latest edition (or the edition indicated) of the following
industry standards and references shall be considered an integral part of this Practice. Short
titles will be used herein when appropriate.
2.1

Process Industry Practices (PIP)

PIP ELSAP11D - Data Sheet for Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

2.2

Industry Codes and Standards

Institute of Electrical and Electronics Engineers (IEEE)
IEE 100 - The IEEE Standard Dictionary of Electrical and Electronics Terms
IEEE 450 - Recommended Practice for Maintenance, Testing, and
Replacements of Vented Lead-Acid Batteries for Stationary Applications
IEEE 485 - Recommended Practice for Sizing Lead-Acid Batteries for
Stationary Applications
Society for Protective Coatings
SSPC-PS 1301 - Epoxy-Polyamide Painting System
Underwriters Laboratories (UL)
UL 94 - Test for Flammability of Plastic Materials for Parts in Devices and
Appliances

2.3

Conflict Resolution
Any conflicts between the referenced documents shall be identified to the Buyer in
writing for resolution. When resolving conflicts, the following order of precedence
shall apply:

Page 2 of 9

Purchase Order

Process Industry Practices

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

April 2001

3.

Data Sheet, PIP ELSAP11D

This Practice, PIP ELSAP11

Referenced Standards

Definitions
For the purposes of this Practice, the following definitions apply:
Note: These definitions are taken from the referenced IEEE standards, including
IEEE 100.
Acceptance Test: A constant current or power capacity test made on a new battery to
determine that it meets specifications or manufacturers ratings
Battery Duty Cycle: The load currents a battery is expected to supply for specified time
periods, end voltage, and temperature
Capacity Test: A discharge of a battery at a constant current or power to a specified terminal
voltage for a specified length of time at 77o F (25o C) or corrected for a different temperature
Cell Size: The rated capacity of a lead storage cell or the number of plates in the cell
Design Margin: Additional capacity allowance in cell size for unforeseen additions to the
DC system and less than optimum operating conditions of the battery or expected growth rate
to the load
Equalizing Voltage: A voltage higher than float, applied to a battery to correct the
inequalities among battery cells (voltage or specific gravity) that may develop in service
Float Voltage: The voltage applied to a battery to maintain it in a fully charged condition
during normal operation
Flooded Cell: A liquid electrolyte filled vented cell
Full Float Operation: Operation of a DC system with the battery, battery charger, and load
all connected in parallel and with the battery charger supplying the normal DC load plus any
self-discharge or charging current, or both, required by the battery
Rated Capacity: The ampere-hour capacity assigned to a lead storage cell by its
manufacturer for a given discharge time, at a specified electrolyte temperature and specific
gravity, to a given end of discharge voltage
Vented Battery: A battery in which the products of electrolysis and evaporation are allowed
to escape freely to the atmosphere. These batteries are also referred to as flooded cell
batteries.

4.

Design
4.1

General
4.1.1

Process Industry Practices

Site conditions are as specified on the Data Sheet.

Page 3 of 9

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

April 2001

4.1.2

Seller shall provide all hardware, connectors, accessories, and racks

necessary for a complete battery system.

4.1.3

The design life of all batteries shall be minimum 20 years in float service at
25 C.

4.1.4

The battery will be connected to a battery charger and to a load bus. In

normal operation, the battery will be in full float operation at the
manufacturers recommended float voltage.

4.1.5

The battery shall endure a minimum of 300 cycles (full charge and
discharge) during its lifetime at the 1-hour discharge rate. The endurance of
a cell or battery shall be stated in terms of the number of full
charge/discharge cycles that the cell can sustain during its useful life. The
cell shall be considered to have reached the end of its useful life when the
ampere-hour capacity drops to 80% of the rated capacity at the 8-hour
discharge rate.

4.1.6

Ampere-hour capacity of the new cell shall be indicated by the Bidder on the
Data Sheet. These data shall be provided for 0.5-, 1-, 5-, and 8-hour
discharge rates, at 25 C, to the final voltage (end-of-discharge voltage) of
1.75 volts. Bidder shall indicate design ambient temperature and maximum
battery float voltage on the Data Sheet.

4.1.7

Battery capacity shall be based on one of the three load options for battery
sizing shown on the Data Sheet. If the load profile option is selected, the
Bidder shall provide the Buyer with the calculations used in selecting the
battery capacity. The method of determining battery capacity shall be as
defined in IEEE 485 for lead-acid batteries. Battery selection shall be based
on 1.75 V minimum per cell.

4.1.8

The number of cells and the nominal voltage of the battery shall be as
specified on the Data Sheet.

4.1.9

The following sizing factors shall be applied to the calculated battery

capacity:

Design margin: 10%

Aging factor: 25%

Note: According to IEEE 450, it is recommended that a battery be

replaced when its actual capacity drops to 80% of its rated
capacity. Therefore, the batterys rated capacity should be at least
125% of the load expected at the end of its service life.

If the specified or calculated battery capacity exceeds a manufacturers

standard rating by more than 5%, the next larger standard rating shall
be selected.

4.1.10 Unless otherwise specified on the Data Sheet, each battery bank shall be
provided with a minimum of two power connection lugs. When specified on
the Data Sheet, each battery bank shall be provided with a power terminal
block solidly mounted to the battery rack for accepting external connections

Page 4 of 9

Process Industry Practices

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

April 2001

to the battery. Connections from the terminal block to the battery shall be
made with extra-flexible, insulated copper cables. Power connection lugs or
terminal block shall accept the quantity and size of incoming cables
specified on the Data Sheet.
4.1.11 Battery shall accommodate a ripple voltage from the charger not exceeding
2% RMS.
4.1.12 Bidder shall indicate on the Data Sheet the maximum hydrogen evolution
when a fully charged battery is equalized from a battery charger whose
output is rated at 25% of the battery 8-hour rating.
4.1.13 Bidder shall indicate on the Data Sheet the maximum fault level available at
the battery terminals.
4.2

Cells
4.2.1

The plate design shall be either tubular or pasted plate lead-calcium alloy,
unless specified otherwise on the Data Sheet. Lead-antimony alloys shall be
no more than 2% antimony. All positive plates shall have retention mats to
restrain the loss of active material caused by repeated cycling.

4.2.2

The cell design shall accommodate the total positive plate growth during the
design life of the cell. The plate growth shall not cause cracking,
deformation, or failure during the lifetime of the cell under normal operating
conditions.

4.2.3

Cell containers and covers shall be made of a high impact, flame-retardant

plastic material having a minimum oxygen index of 28%, and shall meet the
criteria needed to be rated V-0 level when an open flame source is removed,
when tested according to UL 94.

4.2.4

The cover shall be bonded to the container to form a permanent leak-proof

seal.

4.2.5

All cell containers shall be transparent or translucent and shall be

permanently marked with minimum and maximum electrolyte levels.

4.2.6

Terminal posts shall be cast in lead or lead alloy and configured to provide a
reliable, low-resistance interface with the intercell connectors. Cell posts
shall be provided with a composite seal to prevent acid migration to
connectors and container cover.

4.2.7

All cell posts shall have bolted connections. Cell-to-cell connections shall be
made by tin/lead plated copper bus bars using 316L stainless steel hardware.
Step-to-step and tier-to-tier connections shall be made by extra-flexible,
insulated copper cables using 316L stainless steel hardware. Interconnecting
hardware shall be sized to allow discharge current at the 30-minute rate with
no more than 15 mV drop between adjacent cells.

4.2.8

Flame-arrestor type vent plugs with dust caps shall be provided to minimize
the possibility of internal battery explosion being caused by a spark or
battery room fire. The vent plug shall prevent any visible wetting of the cell

Process Industry Practices

Page 5 of 9

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

April 2001

lid when the cell is being overcharged at the equalizing voltage at 25 C

ambient temperature.
4.2.9

The battery bank shall consist of single cells of the required ampere-hour
capacity. Batteries may be paralleled when individual cells weigh more than
100 pounds (45 kilograms). Paralleling of batteries, in all cases, shall be
subject to the Buyers approval.

4.2.10 Electrolyte shall have specific gravity of 1.215 nominal at 25 C when the
cell is fully charged. Sufficient electrolyte shall be supplied to provide full
capacity at all ratings.
4.2.11 All terminal connectors and straps shall be covered with removable clear
insulating material for protection against inadvertent contact with energized
components.
4.3

Page 6 of 9

Battery Racks
4.3.1

Racks shall be constructed of welded structural steel frames with bolted steel
runners and braces, and with provision for anchoring to the floor and the
wall. Side rails and end rails shall be removable. Racks shall be suitable for
the site location seismic zone as indicated on the Data Sheet. Racks shall be
painted with acid-resistant epoxy paint per SSPC-PS 1301, or equivalent.
One pint of touch-up paint shall be provided.

4.3.2

Unless otherwise specified on the Data Sheet, the design shall be a single
tier or two-step arrangement to accommodate all cells. The width of the
racks shall be at least equal to the width of the battery cells. The maximum
installed height of the battery tops above the floor shall be 60 inches or as
specified on the Data Sheet.

4.3.3

All metallic rack components that are in contact with the battery shall be
insulated by removable covers.

4.3.4

Each end of each battery rack shall be drilled near the bottom with two
9/16-inch diameter holes (1-3/4 inches apart) to accommodate Buyers
grounding lugs.

4.3.5

A stainless steel containment pan equipped with a normally-closed drain

valve shall be provided.

4.3.6

Battery rack assembly instructions shall be provided.

Process Industry Practices

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

April 2001

4.4

Accessories
4.4.1

4.4.2
4.5.

Vent-plug mounted thermometer

Hydrometer

Bottle or filling jar with pour spout for adding distilled water

Spare hardware for battery racks and cell terminal connections,

including at least three of each type bolt, nut, and washer required for
rack assembly and hardware for three terminal connections

Cell and battery module lifting devices or slings for installation and
removal of cells and modules weighing more than 50 lbs.

Other accessories shall be supplied as specified on the Data Sheet.

Markings
4.5.1

4.5.2

5.

The following accessories shall be furnished:

The following information shall be permanently marked on each cell or

multi-cell module:

Manufacturers name

Manufacturers catalog number or type reference

Voltage

Capacity (8-hour rate as described in Section 4)

Electrolyte density (fully charged at 25 C)

Date of manufacture

Adhesive number labels shall be provided for the Buyer to use in labeling
the cells.

Inspection and Testing

A constant current or power capacity test, in accordance with IEEE 450, shall be performed
at the factory on all batteries to determine that they meet the specifications. This will
constitute the acceptance test.

6.

Shipping
6.1

Seller shall identify the following on each shipping group:

Purchase order number
Requisition number
Equipment number
Project number

Process Industry Practices

Page 7 of 9

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

7.

April 2001

6.2

Vented lead-acid cells shall be shipped in charged condition. Cells shall be shipped
filled with electrolyte, unless otherwise indicated by Buyer on the Data Sheet.

6.3

Individual cells shall be wrapped and sealed against moisture.

6.4

Individual cell boxes shall be printed with handling instructions including a warning
against lifting the cells by terminal posts.

6.5

Shipping crates and individual cell wrappings shall be marked with instructions for
storage in cool, dry locations.

6.6

Labels on the shipping crate or the outer wrapping shall state the storage conditions,
the date of shipment, and the date beyond which the product must not be stored.

Documentation
7.1

Page 8 of 9

Documentation Content
7.1.1

All engineering data provided for this equipment shall represent the actual
equipment specified and ordered.

7.1.2

Typical drawings are acceptable only if they are revised to identify

specifically the equipment, dimensions, wiring, and accessories being
furnished.

7.1.3

All drawings and data supplied by the Seller shall be identified with Buyers
name, project number, purchase order number, and item number along with
the Sellers shop order number.

7.1.4

Drawings shall have a space on the right hand bottom corner for Buyers title
block.

Process Industry Practices

PIP ELSAP11
Design and Fabrication of Flooded-Cell
Lead-Acid Batteries for Electrical Stations

April 2001

7.2

Drawing and Data Requirements

Seller to provide one (1) reproducible set of drawings plus the specified number of
copies of all documentation and operating manuals as indicated on the Data Sheet.
Unless otherwise specified on the Data Sheet, the format for the reproducible shall
be CAD convertible .dxf electronic format.
A

With
Bid

For
Review

Final
Certified

As
Built

DESCRIPTION

General layout of equipment showing all dimensions,

weights, location; outline drawings showing the final
assembled configuration

Copies of certified test reports

X (1)

Installation, Operation, Maintenance Manual and

required maintenance schedules

X
X

A.
B.
C.
D.

Process Industry Practices

Required purity of the topping-up water and the

electrolyte
X

Safety Instructions clearly identifying proper and

improper operation that might injure personnel and
cause damage to operating equipment

Bidder shall furnish these documents with proposal.

Seller shall furnish these documents for Buyers review and authorization to proceed
before fabrication.
Seller shall furnish these documents as part of the final certified document submittal.
(1) Seller to include one set of installation, operation, and maintenance manuals
with the equipment when shipped.
Seller shall furnish final as-built documents within two weeks following shipment.

Page 9 of 9