TCE Consulting Engineers Limited SECTION:

CONTENTS
TCE.5088A-EL-716-
BS-04 DC, UPS AND EMERGENCY POWER SUPPLY
SHEET i OF i
SYSTEM

CONTENTS

CLAUSE STARTING
DESCRIPTION
NOS. PAGE NO.

1.0 PURPOSE AND SCOPE 1

2.0 DC SYSTEM 1

3.0 UPS SYSTEM 2

4.0 EMERGENCY POWER SUPPLY SYSTEM 3

5.0 LIST OF SKETCHES 4

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 TCE Consulting Engineers Limited SECTION: REVISION
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TCE.5088A-EL-716-
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REVISION STATUS

REV.NO DATE DESCRIPTION

P0 09-08-2007 PRELIMINARY FOR CLIENT’S

APPROVAL

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TCE.5088A-EL-716-
BS-04 DC, UPS AND EMERGENCY POWER SUPPLY
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SYSTEM

1.0 PURPOSE AND SCOPE

1.1 The objective of this study is to present the salient features and the criteria for
selection and sizing of DC, UPS and Emergency Power Supply system to
cater to essential station and unit auxiliary loads of the 4 x 300 MW TPP of
JSW Energy (Ratnagiri) Ltd. at Jaigad, Maharashtra.
2.0 DC SYSTEM
2.1 DC system shall be provided as the most reliable source of power for control,
protection, interlock and annunciation requirements of the power plant during
normal running, as well as for safe shut down of the plant at the time of total
power supply failure.
2.2 The DC system voltage has been selected as 220V DC based on the BTG
package requirements. DC system shall be unearthed for reliability in
continuity of supply.
2.3 Considering the high discharge performance required for power plant
applications and space constraints inside TG building, lead acid plante type
battery is recommended. This will reduce the battery AH capacity requirement
when compared to tubular type lead acid battery (for the same duty cycle)
and also consequent reduction in battery charger rating and space
requirement.
2.4 Unit battery which will cater to the DC supply requirements of the unit shall be
provided for each unit. Also one no. station battery, which will cater to the DC
supply requirements of the common station loads, shall be provided.
2.5 Each battery shall be sized to cater one unit and complete station loads, such
that each unit and station battery banks can act as back up to each other.
2.6 One no. float and boost charger shall be provided for each unit and station
battery along with associated DB. In addition, a standby float and boost
charger shall be provided in Unit 1 & 2 control building which can be switched
to either Unit 1, Unit 2 or station batteries at a time (Refer attached sketch no.
TCE.5088A-EL-SK-012 Rev.P0). Likewise a standby float and boost charger
shall be provided in unit 3 & 4 control building which can be switched to either
Unit 3 or Unit 4 batteries at a time. (Refer attached sketch no. TCE.5088A-
EL-SK-013 Rev.P0). The standby chargers shall be put in service manually if
the main charger fails for whatever reason. The Key One Line Diagram for the
DC system shall be as shown in the attached sketch no. TCE.5088A-EL-SK-
015 Rev.P0.
2.7 The switchyard shall be provided with a separate battery system consisting of
2X100% Float cum Boost chargers with 2X100% lead acid plante type battery
and associated DB (Refer attached sketch no. TCE.5088A-EL-SK-014
Rev.P0).
2.8 Coal/Ash handling system also shall be provided with a separate battery
system consisting of 2X100% Float cum Boost chargers with 2X100% lead
acid plante type battery and associated DB if required.
2.9 Each Unit DCDB shall have two incomers, one from the respective unit
charger and the other from Station DCDB.

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2.10 Battery shall be sized in accordance with IEEE 485-1983 considering

temperature correction factor and design margin of 10%. The correction
factor for ageing shall not be considered as plante type batteries maintain a
fairly constant capacity throughout its life. Minimum battery back up duration
shall be 10 hours and shall be in line with the battery duty cycles applicable
for power plant emergency supplies.
2.11 The boost charger unit shall be rated such that the battery can be charged
from fully discharged condition to fully charged condition within 10 hours.
2.12 Under normal conditions, the float charger shall be connected to the
respective DC switchboard and battery to cater the continuous load of DC
system plus trickle charging current of the battery. In case of AC supply
failure in the plant/to the charger, battery shall meet the DC load. After
restoration of AC supply, the fully / partly discharged battery shall be charged
by boost charger and the float charger shall continue to feed the DC load.
During this period, if AC fails, battery shall feed the load with tapped cell.
2.13 The float and boost charger shall be digital type, programmable with self-
diagnostic with silicon controlled rectifiers and diodes, complete with
resistor/capacitor network for surge protection, connected in three phase full
wave bridge circuit. All set points shall be programmable and the charger
shall be provided with double redundant control channels.
2.14 Charger shall have provision for manual control if the auto mode fails. Load
limiting features shall be provided. The charger shall be designed for
adequate short time over load to take care of the starting of the largest DC
motor/testing of lamps, etc. with other DC loads connected to bus.
2.15 The chargers shall be provided with automatic voltage regulation in float
mode and automatic constant current regulation in boost mode.
2.16 The chargers shall be natural air-cooled and no external fans shall be
provided to dissipate the heat developed within the panel. The main
transformer of the charger can be mounted in a separate enclosure to reduce
heating inside the charger.
2.17 The batteries shall be located on wooden stands in well ventilated battery
rooms.
3.0 UPS SYSTEM

3.1 The UPS (Uninterrupted Power Supply) system shall be provided to feed
critical AC loads which have stringent requirements on voltage, frequency and
transient recovery time.
3.2 The UPS system voltage has been selected as 220V AC based on the BTG
package requirements.
3.3 Separate UPS systems of the same configuration as mentioned in Cl.No.3.5
below shall be provided for each unit (for BTG and BOP loads), DM Plant,
CHS/AHS and Switchyard according to the loads.

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3.4 The UPS system shall be of static type, basically composed of solid state
rectifier-chargers, battery back up, static inverters, static switches for added
protection and transfer of loads with no break or with minimum interruption of
the order of the fraction of a cycle during under voltage condition to the
healthy inverter. The components of UPS shall isolate power line voltage
transients, frequency variations and high/low voltage conditions from the
critical load and act a line filter and voltage regulator, apart from providing no-
break power at constant frequency during normal AC power outage.
3.5 Each UPS system shall have Parallel Redundant UPS (designated as UPS1
and UPS2) with SCVS (Servo Controlled Voltage Stabiliser) bypass
configuration as shown in the attached sketch no. TCE.5088A-EL-SK-016
Rev.P0. Each UPS (UPS1 and UPS2) and SCVS shall be rated for supplying
100% loads. Static switches for smooth and interruption free changeover and
manual maintenance bypass switch shall be provided for each UPS. Each
UPS shall have one no. (1) 100% rated rectifier, inverter, and one no. (1)
100% rated battery. The combination of one no. rectifier, one no. battery bank
and one no. inverter along with the necessary static and manual bypass
switches shall be considered as a branch circuit.
3.6 Lead Acid Plante type batteries shall be given for UPS, in line with the
batteries for DC system.
3.7 Each UPS system shall be provided with a UPS ACDB, having two nos.
MCCB incomers and a MCCB bus coupler. The bus coupler shall be normally
open with each UPS (UPS 1 and UPS 2) feeding approximately 50% loads.
3.8 During normal operation, both UPS1 and UPS2 shall run in synchronism with
the SCVS voltage and frequency, taking 50 % load. On failure of mains
supply, both UPS1 and UPS2 shall run in synchronism with the system
generated voltage and frequency reference using the battery back up. Battery
shall be rated to provide back up time of 60 minutes.
3.9 On occurrence of any fault on one UPS, the static switch shall immediately
switch the SCVS supply to the loads and isolate the faulty UPS so that there
is no interruption at the load end. The entire load can then be manually
switched over to the healthy UPS (if required), by closing the ACDB bus
coupler and opening the incomer from the faulty UPS. The load on the UPS
can also be manually transferred to the SCVS for UPS maintenance by
closing the maintenance bypass switch and opening the UPS output switch.
4.0 EMERGENCY POWER SUPPLY SYSTEM
4.1 An Emergency DG (Diesel Generator) set shall be provided for each unit to
cater to the requirements of emergency loads during unit black out conditions.
4.2 The voltage of the Emergency DG shall be 415V in line with the LT system
voltage for the plant.
4.3 All unit emergency loads shall be grouped and fed from a bus designated as
Normal / Emergency (N/E) bus, which is an extension of the Unit Service
Switchgear (USS). The scheme of supply shall be as shown in the attached
sketch no. TCE.5088A-EL-SK-017 Rev.P0.
4.4 Under normal operating conditions, emergency loads connected to N/E bus
shall be fed from the normal source (i.e. USS-B) by closing the bus coupler
between USS-B and N/E bus, and the incomer from DG set shall remain
open.
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4.5 On loss of normal power supply, No Voltage relay actuated timer will trip the
bus coupler between USS-B and N/E bus, close the incomer to N/E bus from
the DG AMF (Automatic Mains Fail) panel and at the same time give starting
impulse for the DG set. When the DG set reaches the rated speed and
voltage, the breaker on the DG AMF panel shall close automatically, provided
the bus coupler between USS-B and N/E bus has opened.
4.6 On restoration of normal supply, the N/E bus will be charged from USS-B by
manual synchronisation between N/E bus and USS-B thereby closing the bus
coupler between USS-B and N/E bus. DG incomer breaker to N/E bus will be
tripped manually after this synchronisation and the DG set will be switched off
manually thereafter.
4.7 The DG AMF panel will be placed in the same room as the DG set. For
routine check up of the DG set, facility shall be provided on the DG AMF
panel to start, raise and lower the speed and raise and lower the voltage. To
facilitate this, an Auto/Manual selector switch shall be provided at the AMF
panel. When selected in Auto, the DG set operation shall be automatic as
explained in Cl.No.4.5 above. When selected in Manual, the DG set operation
shall be done locally from the AMF panel with control facilities as mentioned
above. No facility for synchronisation shall be provided on the AMF panel and
hence no load testing is envisaged during routine check up. The facility for
routine checking is kept only at the AMF panel so that the operator can
visually verify the operation of the engine and the alternator. It may be noted
that when the DG set is taken for routine check up by selecting the
Auto/Manual selector switch in Manual, the DG backup will not be available
for unit blackout. Annunciation shall be provided at the unit control room to
annunciate the selection of the Auto/Manual selector switch in Manual, so that
the switch is not left in manual position by mistake after routine check up.
4.8 The restarting of the emergency motors shall be done from the DCS system,
either automatically or manually, once the DG power supply is available at the
N/E bus after a blackout. Hence no emergency type modules with time
delayed contactor drop out feature will be provided in the N/E bus.
5.0 LIST OF SKETCHES ATTACHED
5.1 TCE.5088A-EL-SK-012 Rev.P0 – Float and Boost charger with 1X100%
battery (For Units 1, 2 and Station).
5.2 TCE.5088A-EL-SK-013 Rev.P0 – Float and Boost charger with 1X100%
battery (For Units 3 and 4).
5.3 TCE.5088A-EL-SK-014 Rev.P0 – Float cum Boost charger with 2X100%
battery.
5.4 TCE.5088A-EL-SK-015 Rev.P0 – Key One Line Diagram 220 V DC system.
5.5 TCE.5088A-EL-SK-016 Rev.P0 – Parallel Redundant UPS system (for each
unit) with SCVS static by pass.
5.6 TCE.5088A-EL-SK-017 Rev.P0 – Typical scheme for Emergency DG set
connection for each unit.

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