Battery and Charger Sizing

CONTENTS

SECTION DESCRIPTION

1.0 PURPOSE

2.0 CODES & STANDARDS

3.0 DESIGN INPUTS

4.0 ASSUMPTIONS / CONSIDERATIONS

5.0 RESULTS

6.0 BATTERY LOAD CYCLE

7.0 BATTERY LOAD CURVE

8.0 DETERMINATION OF NO. OF CELLS

9.0 DETERMINATION OF AH RATING OF BATTERY

10.0 DETERMINATION OF RATING OF BATTERY CHARGER

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 Battery and Charger Sizing

1.0 PURPOSE :

The purpose of this calculation is (a) to establish Battery load Cycle, (b) to calculate the no. of cells required for 220 V DC, (c) to
calculate AH rating of 220 V DC Battery for ststion auxiliary loads, and the rating of Battery Charger for 2 X 15 MW Muri, Co-
Generation Plant, Jharkhand, India.

2.0 CODES & STANDARDS

(a) IEEE-485, 1997 - IEEE Recommended Practice for Sizing of Lead Acid Batteries for Stationary Applications

(b) IEEE-946 - IEEE Recommended Practice for the Design of DC Auxiliary Power Systems for Generating Stations

3.0 DESIGN INPUTS

(a) 1 x 100 % Battery and 2 x 100 % Battery Charger are considered for 220V DC system.

(b) Plante type Lead Acid station batteries are considered.

(c) The End Cell Voltage (ECV) is considered as 1.85 V/cell in the battery

(d) Battery is sized for maximum one (1) hour of duty as per specification

(e) Temperature correction factor shall be calculated based on minimum site temperature 5 degC with respect to
the standard temeperatute 27 degC.
(f) A design margin of 10% has been considered for unforeseen additions and future growth.

(g) An aging factor of 1.00 has been considered in sizing the battery as per IEEE : 485 - 1997, cl. no. 6.2.3

(h) Cell voltage required for float charging is taken as 2.15 V/Cell as per specification.

4.0 ASSUMPTIONS / CONSIDERATIONS

(a) Breaker tripping coil loads have been considered as 1 minute duration loads (Duty Cycle: 0-1 min.) as per
standard engineering practice

(b) Breaker closing coil and spring charging motor loads have been considered as 1 minute duration loads
(Duty Cycle: 59-60 min.) as per standard engineering practice.

(c) Emergency DC lighting load has been considered as continuous load ( Duty cycle : 0 - 60 min.)

(d) Local LED indications, protective relays, trip relays, timers, other aux. Relays, control panel supply and
emergency lube oil pump, have been considered as continuous loads (Duty Cycle: 0-60 min.) as per standard
engineering practice and system requirements.

(e) For emergency lube oil pump, motor have been considered with 85% efficiency. The starting current has been
been considered 2 times of respective full load current.

(f) The value of ‘K’ factor has been considered as per Vendor’s data.

(g) The rated current of each battery charger will be such that it is capable of supplying the continuous load
current and re-charging a fully discharged battery at eight (8) hour.
(h) The duty cycle does not include any spare capacity as this is accounted for by the design margin .

i) The percentage change of capacity on discharge with temperature for PLANTE' type battery has been
considered as 0.9 as per reputed manufacturer's data.

5.0 RESULTS

(a) Rating of each station battery is 645 AH (Minimum) (Refer note-1)

(b) The no. of cell of each battery is 102

(c) Rating of each station battery charger is 175 Amp

Note:

1) Aging factor 1.00 has been considered as per IEEE-485. However, if Manufacturer recommends aging factor, the
uncorrected AH capacity shall be multiplied by Aging factor 1.25 to get the final AH capacity of the battery.

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 Battery and Charger Sizing

6.0 BATTERY LOAD CYCLE

BATTERY LOAD CYCLE: 220V DC BATTERY

Type Unit No. of From To From
Sl. Load Total 0 1 1
of Load Simultaneous
No. Description Nos.
Load (A) Operation Minute load (A) Minute load (A)
A Turbine Auxiliaries
1 Emergency Oil Pump (12 kW) Continuous 64.17 3 3 385.03 192.51
B Generator
1 Generator Excitation System(Assumed) Continuous 1.00 2 2 2.00 2.00
2 Generator Protection Panel (Assumed) Continuous 1.00 2 2 2.00 2.00
3 CO2 System Continuous 2.00 2 2 4.00 4.00
C 11 kV Switchgear
Spring charging motor of 11 kV Breaker
1 Momentary 1.14 15 1
( 250 W)
2 Closing coil of 11 kV Breaker (250 W) Momentary 1.14 15 1
3 Tripping of 11 kV Breaker ( 500 W) Momentary 2.27 15 15 34.09
Control supply, indication circuit and
4 protective relays for 15 nos breakers @ 0.3 Continuous 0.30 15 15 4.50 4.50
A each for 11 kV switchgear
D 6.6 kV Station Switchgear
Spring charging motor of 6.6 kV Breaker
1 Momentary 1.00 8 1
( 220 W)
2 Closing coil of 6.6 kV Breaker (440 W) Momentary 2.00 8 1
3 Tripping of 6.6 kV Breaker (440 W) Momentary 2.00 8 6 12.00
Control supply, indication circuit and
4 protective relays for 8 nos breakers @ 0.3 A Continuous 0.30 8 8 2.40 2.40
each for 6.6 kV switchgear
E 415 V Station Switchgear
Spring charging motor of 415 V Breaker
1 Momentary 1.00 18 1
( 220 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 18 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 18 13 6.50

Control supply, indication circuit and

4 protective relays for 18 nos breakers @ 0.3 Continuous 0.30 18 18 5.40 5.40
A each for 415 V switchgear

F 415 V Boiler MCC#1

Spring charging motor of 415V Breaker

1 Momentary 0.91 3 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 3 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 3 2 1.00

Control supply, indication circuit and

4 protective relays for 3 nos breakers @ 0.3 A Continuous 0.30 3 3 0.90 0.90
each for 415 V switchgear

G 415 V Boiler MCC#2

Spring charging motor of 415V Breaker

1 Momentary 0.91 3 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 3 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 3 2 1.00

Control supply, indication circuit and

4 protective relays for 3 nos breakers @ 0.3 A Continuous 0.30 3 3 0.90 0.90
each for 415 V switchgear

H 415 V Boiler MCC#3

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 Battery and Charger Sizing

BATTERY LOAD CYCLE: 220V DC BATTERY

Type Unit No. of From To From
Sl. Load Total 0 1 1
of Load Simultaneous
No. Description Nos.
Load (A) Operation Minute load (A) Minute load (A)
Spring charging motor of 415V Breaker
1 Momentary 0.91 3 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 3 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 3 2 1.00

Control supply, indication circuit and
4 protective relays for 3 nos breakers @ 0.3 A Continuous 0.30 3 3 0.90 0.90
each for 415 V switchgear
I 415 V Water MCC
Spring charging motor of 415V Breaker
1 Momentary 0.91 2 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 2 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 2 1 0.50

Control supply, indication circuit and
4 protective relays for 2 nos breakers @ 0.3 A Continuous 0.30 2 2 0.60 0.60
each for 415 V switchgear

J 415 V ESP MCC

Spring charging motor of 415V Breaker

1 Momentary 0.91 2 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 2 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 2 1 0.50

Control supply, indication circuit and
4 protective relays for 2 nos breakers @ 0.3 A Continuous 0.30 2 2 0.60 0.60
each for 415 V switchgear

K 415 V Ash Handling MCC

Spring charging motor of 415V Breaker

1 Momentary 0.91 2 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 2 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 2 1 0.50

Control supply, indication circuit and
4 protective relays for 2 nos breakers @ 0.3 A Continuous 0.30 2 2 0.60 0.60
each for 415 V switchgear

L 415 V STG MCC#1

Spring charging motor of 415V Breaker

1 Momentary 0.91 3 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 3 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 3 2 1.00

Control supply, indication circuit and
4 protective relays for 3 nos breakers @ 0.3 A Continuous 0.30 3 3 0.90 0.90
each for 415 V switchgear

M 415 V STG MCC#2

Spring charging motor of 415V Breaker

1 Momentary 0.91 3 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 3 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 3 2 1.00

Control supply, indication circuit and
4 protective relays for 3 nos breakers @ 0.3 A Continuous 0.30 3 3 0.90 0.90
each for 415 V switchgear

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 Battery and Charger Sizing

BATTERY LOAD CYCLE: 220V DC BATTERY

Type Unit No. of From To From
Sl. Load Total 0 1 1
of Load Simultaneous
No. Description Nos.
Load (A) Operation Minute load (A) Minute load (A)

N 415 V BOP MCC

Spring charging motor of 415V Breaker

1 Momentary 0.91 2 1
(200 W)
2 Closing coil of 415 V Breaker (110 W) Momentary 0.50 2 1

3 Tripping of 415 V Breaker (110 W) Momentary 0.50 2 1 0.50

Control supply, indication circuit and
4 protective relays for 2 nos breakers @ 0.3 A Continuous 0.30 2 2 0.60 0.60
each for 415 V switchgear
O Intercommunication Continuous 5.00 5.00 5.00
P Emergency Lighting Continuous 20.00 20.00 20.00
Q Miscellaneous Loads Continuous 10.00 10.00 10.00
Total load in Amps. 506.82 254.71

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 Battery and Charger Sizing

RY
To From To Continuous
59 59 60 Load (A) Remarks
Minute load (A) Minute load (A)

192.51 192.51

2.00 2.00 2.00

2.00 2.00 2.00
4.00 4.00 4.00

1.14

1.14

4.50 4.50 4.50

1.00

2.00

2.40 2.40 2.40

1.00

0.50

5.40 5.40 5.40

0.91

0.50

0.90 0.90 0.90

0.91

0.50

0.90 0.90 0.90

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 Battery and Charger Sizing

RY
To From To Continuous
59 59 60 Load (A) Remarks
Minute load (A) Minute load (A)

0.91

0.50

0.90 0.90 0.90

0.91

0.50

0.60 0.60 0.60

0.91

0.50

0.60 0.60 0.60

0.91

0.50

0.60 0.60 0.60

0.91

0.50

0.90 0.90 0.90

0.91

0.50

0.90 0.90 0.90

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 Battery and Charger Sizing

RY
To From To Continuous
59 59 60 Load (A) Remarks
Minute load (A) Minute load (A)

0.91

0.50

0.60 0.60 0.60

5.00 5.00 5.00

20.00 20.00
10.00 10.00
254.71 274.17 32.20

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 Battery and Charger Sizing

time current
0 0
SEC : 7 -BATTERY LOAD CYCLE
0 506.8176
1 506.8176
1 254.7134
600
59 254.7134
59 274.1679
60 274.1679
60 0
CURRENT IN AMP

500
0 0
0 0
0 0
0400 0
0 0
0 0
0 0
0300 0

200

100

0
0 20 40 60 80
TIME IN MIN

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 Battery and Charger Sizing

LE

60 80

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 Battery and Charger Sizing

8.0 DETERMINATION OF NUMBER OF CELLS

Nominal cell voltage : 2 volts (as per reputed manufacturer's catalogue)

Nominal battery voltage : 220 volts

Float voltage : 2.15 volts

End cell voltage : 1.85 volts (as per reputed manufacturer's catalogue)

System DC voltage variation : 220V, + 10% to - 15%

= 242.00 volts to 187.00 volts

Boost voltage : 2.75 volts (as per reputed manufacturer's catalogue)

Number of cells determined considering the minimum system voltage and end cell voltage =

Minimum System Voltage =187/1.85 = 101.08 ……..(i)

End Cell Voltage

Number of cells determined considering the maximum system voltage and float voltage =

Maximum System Voltage =242/2.15= 112.56 ……..(ii)

Float Charging Voltage

Number of cells chosen is lower of the values as per eq (i) & (ii) = 101.08

= 102 Taken

Maximum system voltage considering 102 cells and float voltage of 2.15 volts =

102 x 2.15 = 219.3 volts

< 242.00 volts

Minimum system voltage considering 102 cells and end cell voltage of 1.85 volts =

102 x 1.85 = 188.7 volts

> 187.00 volts

Hence, selection of 102 cells is justified.

9.0 DETERMINATION OF AH RATING OF BATTERY

9.1 CORRECTION FACTORS FOR BATTERY SIZING

For arriving at the battery AH capacity, the following correction factors have been considered:

a) Temperature derating factor at minimum site temperature 5 deg C ( From reputed manufacturer' data)

Standard temperture in deg C = 27

Minimimum site/ electrolyte temperature in deg C = 5

% change of capacity on discharge with temperature for PLANTE' type battery = 0.9

Temperature correction factor = 1 + 0.9/100(27-5) = 1.198

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 Battery and Charger Sizing

b) Capacity Factor (KT) with end cell voltage of 1.85 V/ cell) ( From reputed manufacturer's
catalogue )

Duration (min.) Temperature derating factor, Tt Capacity Factor (KT)

1.00 1.198 1.25

58.00 1.198 1.893

59.00 1.198 1.897

60.00 1.198 1.90

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 Battery and Charger Sizing

9.2 BATTERY SIZING CALCULATION

End Cell Voltage : 1.85 volts
Minimum Site Temperature : 5 Deg. C
Battery Nominal Voltage : 220 V
Nominal cell voltage : 2.0V per cell
Cell type : Plante' type Lead Acid Battery
Total Duration : 60 Min.
Load Details :
A1 = 506.8 Amp
A2 = 254.7 Amp
A3 = 274.2 Amp

[1] [2] [3] [4] [5] [6]

Period Load Change in Duration Of Time End of Section Capacity Factor at t
Load Period Min. rate (KT)

Section 1: First Period Only - if A2 is greater than A1, go to Section 2

1 A1= 506.8 506.8 M1=1 t=M1=1 1.250
Section 1

Section 2: First Two Periods Only- If A3 is greater than A2, go to Section 3

1 A1= 506.8 506.8 M1= 1 t= M1 + M2 =59 1.897
2 A2= 254.7 -252.1 M2 = 58 t= M2 = 58 1.893
Section 2

Section 3 : First Three Periods Only - if A4 is greater than A3, go to Section 4

1 A1= 506.8 506.8 M1 = 1 t= M1 + M2 + M3 = 60 1.900
2 A2= 254.7 -252.1 M2 = 58 t=M2 + M3 = 59 1.897
3 A3= 274.2 19.5 M3 = 1 t = M3 = 1 1.250
Section 3

Uncorrected Cell Size = Maximum Section Size = 759.0

Design Margin = 10%
Aging Factor = 1.00
Cell Size (Uncorrected Cell Size) * (Design Margin) * (Aging Factor) = 834.9

Minimum AH rating of Battery selected 645

10.0 DETERMINATION OF RATING OF BATTERY CHARGER

Each station battery charger has been sized in accordance with the following formulas :

I1 = LC + 1.1 AH / T ------------ (1)

I2 = LC + Ln ------------------------(2)

where

I1 = the minimum required charger rated output ( Amp)

I3 = the recommended charger rated output ( Amp); I.e, the larger of I1 or I2

LC = the continuous DC load ( Amp ), including future load growth 40.25

Ln = the largest combination of noncontinuous loads that would likely be connected to

the bus simultaneously during normal plant operation. (Amp) 192.51

1.1 = Battery Inefficiency Factor (for Lead Acid batteries)

AH = The ampere-hours discharged from battery. 645.00

T = the time to recharge the battery to approximately 95% of capacity ( in hours) 8.00

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 Battery and Charger Sizing

I1 = 40.25 + [ 1.1 x 645 /8 ] = 128.94 (Amp) From eq. No. (1),

I2 = 40.25 +192.513 = 232.76 (Amp) From eq. No. (2),

I3 = Recommended charger out put, larger of I1 or I2 = 232.76 (Amp)

Charger Rating Selected at 220 V DC 175 Amp

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 Battery and Charger Sizing

[7] [8]
Temp Derating Factor Required Section Size =
for t Min. (Tt) (3)x(6)x(7) = Rated AH.
Pos. Values Neg. Values

1.198 759.0
Total (AH) 759.0

1.198
1.198
Sub. Total
Total (AH)

1.198 1153.6
1.198 -572.9
1.198 29.1
Sub. Total 1182.8 -572.9
Total 609.8

AH

Considering 25% design margin

(Assumed)

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