TNB Integrated Learning Solution (ILSAS)

132kV PROTECTION COMPETENCY COURSE

 TNB Integrated Learning Solution (ILSAS)

SUBSTATION AUXILIARY -
DIRECT CURRENT (DC)
SYSTEM
 TNB Integrated Learning Solution (ILSAS)

OBJECTIVE
With reference to TNB Transmission system and
practices, upon completion of this training
session, trainees shall be able to:
1. Define the main purpose & components of
DC system
2. Define the design philosophy of Transmission
Substation DC system
2. Define types of DC distribution system
3. Define types of battery cells & their
advantages
4. Define the components of charger system
 TNB Integrated Learning Solution (ILSAS)

CONTENT
1. Introduction of DC System
- Purpose
- Components and Arrangement of DC System

2. Design Philosophy & Guideline of Substation Dc

System

3. Battery Cells
- Type of Cells : Nickel Cadmium & Lead Acid
- Ampere-hour (Ah) Rating and Calculation
 TNB Integrated Learning Solution (ILSAS)

CONTENT(con’t)
4. Charger
- Type of charger
- Principle of Operation
- Charger Components
 TNB Integrated Learning Solution (ILSAS)

INTRODUCTION OF DC SYSTEM
• Provides reliable source of auxiliary power
to substation secondary equipments
• Provides continuity of service in the event
of temporary interruption of AC supplies
• Provides an independent power source for
substation secondary equipments, which
does not vary with power system voltage
for fault clearing system
 TNB Integrated Learning Solution (ILSAS)

DC SYSTEM CONFIGURATION
DC System Type Advantages Disadvantages
AC Low capital Cost • No standby DC
DC
• Require to isolate the
load to boost the
battery

1 X 100% Charger and 1 X 100% battery

AC AC
Medium capital cost 50% capacity on loss of
DC DC Standby DC provided one battery during AC
during loss of AC supply source failure.

Semi Duplicate:
2 X 50% battery and 2 X 100% chargers
 TNB Integrated Learning Solution (ILSAS)

DC SYSTEM CONFIGURATION
DC System Type Advantages Disadvantages
Full 100% standby DC High capital cost.
AC AC capacity provided under
all AC source conditions
DC DC

and single component

(charger or battery)
failure.

Fully Duplicate
2 X 100% batteries and 2 X 100%
Chargers
 TNB Integrated Learning Solution (ILSAS)

TYPICAL DC SYSTEM SINGLE LINE DIAGRAM

240Vac or 415Vac
depending on
MCB
charger rating MCB

Indicators Indicators
& Relays & Relays
Interlock
Charger No. 1 Charger No. 2

Anti-power Anti-power
Indicators Indicators
reversal device reversal device

Battery Bank Battery Bank

No. 1 No. 2
Indicators
& Relays Nominal 110Vdc Indicators
& Relays
Float 121Vdc
End Voltage 99Vdc
MCB (after 8hr) MCB
Voltage Drop 5Vdc
DC Busbar

MCB MCB

DC Distribution Board

DC Distribution DC Distribution
Feeder No. 1 Feeder No. n
 TNB Integrated Learning Solution (ILSAS)

TRANSMISSION DESIGN
PHILOSOPHY & GUIDELINE
FOR SUBSTATION DC SYSTEM
 TNB Integrated Learning Solution (ILSAS)

DESIGN PHILOSOPHY FOR SUBSTATION DC SYSTEM

1. Substation DC system should be fully duplicated

with redundant chargers and two battery banks
2. Each system should have sufficient capacity to
meet the total requirements (standing load,
transient load & spare for future extension &
design margin error)
3. Batteries are continuously charged and subject
to infrequent discharges
 TNB Integrated Learning Solution (ILSAS)

DESIGN CONSIDERATIONS & CONSTRAINTS

1. Substation layout :
- One DC system for 275kV & below (provided all
secondary equipment is housed in one building)
- One dedicated DC system for 500kV system
2. Nominal system voltage should be 110VDC but not
more than 125VDC & not less than 99VDC during
normal service operation
3. DC system should be fully duplicated with each bank
has sufficient capacity to supply continuously within
standby period under all AC supply condition & charger
failure
 TNB Integrated Learning Solution (ILSAS)

DESIGN CONSIDERATIONS & CONSTRAINTS

4. Normal standing load during standby period is defined
as the period battery is required to perform without
recharged

5. Transient load is classified into 2 groups, i.e. 1s and 1

minute
6. For extension works which require upgrade of DC
system, new DC source should be able to cater for both
existing load & new load

7. DC system should be continuously monitored to detect

abnormal voltage levels (high & low), DC grounds &
loss of AC
 TNB Integrated Learning Solution (ILSAS)

DC DISTRIBUTION REQUIREMENTS
1. The protection DC circuit for each bay should be
duplicated ; i.e. two independent protection circuits
2. DC circuits at each bay level should be independent &
separate from other DC circuits
3. Busbar protection and circuit breaker failure schemes
should be provided with an independent DC circuit
4. Voltage drop in the DC system should be kept within
acceptable limits
5. Each DC circuit should be supervised & monitored by
DC supervision system
6. DC and AC circuits should be segregated
 TNB Integrated Learning Solution (ILSAS)
DC DISTRIBUTION REQUIREMENTS
Rated Bay Circuits from DC Protection & Control Panel DC
DB circuits
132kV Circuit 1 Main 1 Protection System
Circuit Breaker Failure
Circuit 2 Back Up Protection System
Control System or Bay Controller
Outdoor switchgear auxiliary supplies
275kV & above Circuit 1 Main 1 Protection System
Control System
Backup Protection System (Circuit
Breaker Failure)
Circuit 2 Main 2 Protection System
Backup Protection System ( except
Circuit Breaker Failure)
Bay Controller
Outdoor switchgear auxiliary supplies
 TNB Integrated Learning Solution (ILSAS)

BATTERY TECHNICAL REQUIREMENT

1. DC system should consist 2 identical & equally rated
battery banks
2. Minimum standby period for which a battery bank is
required to perform without recharge should be 8
hours
3. End of standby period, battery bank should have
sufficient capacity for 2 sequential closing & 2 tripping
of all circuit breakers
4. DC system voltage should not drop to less than 99V
with standing loads still connected
5. Battery cell type should be of Nickel Cadmium (NiCd) of
low resistance type
 TNB Integrated Learning Solution (ILSAS)

CHARGER TECHNICAL REQUIREMENT

1. Each battery charger should be dual charger with
AC/DC rectifier control operating in parallel
2. Charger can be single-phase, 240 volts or three-phase
415 volts depending on substation load requirement &
battery capacity
3. During normal service, 2 chargers should be in parallel
& share the substation load
4. Each charger should be adequately rated for continuous
supply of standing load & also should have excess to
recharge it’s own battery
5. During normal operation, if any of the 2 battery charges
is required to boost charge, the load should be
automatically disconnected.
 TNB Integrated Learning Solution (ILSAS)

CHARGER TECHNICAL REQUIREMENT

6. In boost charge mode, charger should be able to revert
to float mode upon completing the boost charge cycle.
7. Boost charge should be blocked when one charger fails
8. Only one charger is allowed to charge at any one time
9. During normal operation, the float charge facility should
be able to compensate self-charging & maintain it’s
battery bank in fully charged condition
10. Alarms as the per table should be made available for
remote monitoring
 TNB Integrated Learning Solution (ILSAS)

CHARGER INDICATION REQUIREMENT

Indication Indicator
Voltmeter Charger Output, DC Voltage
Charger Input, AC Voltage
Battery Output, DC Voltage
Ammeter Load Output, DC Current
Battery Output, DC Current
Selector Switch Float/Boost/Auto Selection
MCB AC Mains ON/OFF Input
DC Mains ON/OFF Output
 TNB Integrated Learning Solution (ILSAS)

CHARGER ALARM REQUIREMENT

Indication Indicator Color
Neon AC Mains On GREEN
LED Charger Fail RED
Charger on Float WHITE
Charger on Manual Boost WHITE
Charger on Automatic YELLOW
Boost
Earth Fault RED
Battery Low Electrolyte YELLOW
Level
Battery Voltage Low RED
Battery Voltage High RED
 TNB Integrated Learning Solution (ILSAS)

BATTERY FOR SUBSTATION DC

SYSTEM
 TNB Integrated Learning Solution (ILSAS)

INTRODUCTION
• The battery functions as the heart of a dc power system
and is the only source of electrical energy upon a loss of
normal and backup (if applicable) ac power
• Only lead-acid and Nickel-Cadmium batteries satisfy the
low cost, high reliability, and long life requirements expected
for stationary applications
• Cost and operating life are the limiting factors preventing
commercialization of other battery technologies for
stationary applications
 TNB Integrated Learning Solution (ILSAS)

STATIONARY BATTERY TYPES

PRIMARY SECONDARY
(NON- (RECHARGEABLE)
RECHARGEABLE)

VENTED LEAD-ACID VALVE-REGULATED

LEAD-ACID (VRLA) VENTED NICKEL-
Plate Construction
Type: (SEALED LEAD-ACID) CADMIUM (NiCd)
• Plante Plate Plate Construction
• Modified Plante Plate Type:
• Absorbed Electrolyte Type:
• Round Plate • Pocket Plate
• Tubular Plate • Gelled Electrolyte
• Sintered Plate
• Fiber Plate
 TNB Integrated Learning Solution (ILSAS)

COMPARISON BETWEEN NiCd AND LEAD ACID

Vented NiCd Vented Lead Acid Sealed Lead Acid (VRLA)
Advantages
•Long Life (20-25 years) •Less Expensive •Less Maintenance On The Cells
•Easy Maintenance •High Transient Capability (Require No Electrolyte Toping)
•Does Not Require Air •Does Not Require Air •Does Not Require Ventilation
Condition. Max. Operating Condition. Operating
Temperature 45 Deg. C Temperature Up To 45 Deg. C
•Better Mechanical Strength •Higher Cell Voltage. Require
•Very High Transient Capability Less Cells (~60 cells for
•Able To Be Overcharged With 110Vdc System)
No Damage To Battery
•Low Space and Weight
•Low H2 Discharged with No
Spillover Issue
•Very High Cyclic Up to 1000
cycles at 80% Depth of
Discharged DOD
•No Sudden Death

COMPARISON BETWEEN NiCd AND LEAD ACID
Vented NiCd
•More Expensive
•Require Electrolyte Toping
•Require Ventilation
•Lower Cell Voltage. Require
More Cells (~87 – 88 cells for
110Vdc System)
•Memory Effect. Require Full
Discharge.
•Require Higher Charging
Current
•Higher Distilled Water
Consumption
TNB Integrated Learning Solution (ILSAS)
Vented Lead Acid
Disadvantages
•Shorter Life (Plante Type -15-
20 years)
•Require Electrolyte Toping
•Require Ventilation
•Hydrogen H2 Gas and
Corrosive Sulfuric Gas
Released Esp. When Boosting
•Sudden Death With No Initial
Sign Of Failure
•Sulfuric Acid Electrolyte –
Difficult to Handle and
Require Anti Acid Flooring
•Very Minimum Cyclic Up To
200 Cycles at 80% DOD
Sealed Lead Acid (VRLA)
•Require Maintenance to
Maintain Room Environment or
Conditions. Air Condition
required to Maintain Temperature
20-25 deg. C
•Shorter Life (5-10 years)
•Hydrogen H2 Gas and Corrosive
Sulfuric Gas May Be Released If
Overcharged
•Low Transient Capability
•Sudden Death With No Initial
Sign Of Failure
•Very Minimum Cyclic Up To
200 Cycles at 80% DOD
 TNB Integrated Learning Solution (ILSAS)

NICKEL-CADMIUM BATTERY CELL

Pocket Plate Vented

or Flooded NiCd
 TNB Integrated Learning Solution (ILSAS)

NICKEL-CADMIUM BATTERY

Electrolyte – Potassium Hydroxide (KOH)

Positive Plate – Negative Plate –

Nickel (Ni) Cadmium (Cd)

+ -
 TNB Integrated Learning Solution (ILSAS)

CHEMICAL REACTION (NiCd FULL CELL REACTION)

Discharge Charge
AC AC
DC DC

+ + + -
- - -
- +- + -
++ + --
+
- - + -
+ +
charge
2Ni(OH)3 + Cd + 2H2O 2Ni(OH)2 + Cd(OH)2
Positive Negative Water discharge Positive Negative
Plate Plate Plate Plate
 TNB Integrated Learning Solution (ILSAS)

NICKEL-CADMIUM BATTERY STANDARD

Standards Description Cell Type

IEC 60623 Secondary cells and batteries
(2001) containing alkaline or other
non-acid electrolytes – Vented
nickel-cadmium prismatic
rechargeable
Low rate of discharge (L)
Medium rate of discharge (M)
High rate of discharge (H)
Very high rate of discharge (X)
 TNB Integrated Learning Solution (ILSAS)

NICKEL-CADMIUM CHARGING TIME

 TNB Integrated Learning Solution (ILSAS)

NICKEL-CADMIUM DISCHARGED CURVES

 TNB Integrated Learning Solution (ILSAS)
NICKEL-CADMIUM DISCHARGED TIME
 TNB Integrated Learning Solution (ILSAS)

BATTERY CHARACTERISTICS

Vented NiCd Vented Lead Acid

Nominal Voltage 1.43 – 1.50 volts/cell 2.13 – 2.18 volts/cell
Float Charge Voltage 1.40 – 1.47 volts/cell 2.20 – 2.25 volts/cell
Boost Charge Voltage 1.60 – 1.70 volts/cell 2.35 – 2.40 volts/cell
Final Discharge Voltage 1.14 volts/cell 1.75 volts/cell
 TNB Integrated Learning Solution (ILSAS)

FAILURE OF NICKEL CADMIUM BATTERIES

• In general, nickel-cadmium batteries fail because of

gradual aging of the active materials in the plates
• Nickel-cadmium batteries have a reputation for long life
and high reliability
• The actual operating lifetime, varies from 8 to over 25
years, depends on the service environment and application
• Overcharging results in excessive gassing, which requires
more frequent watering, but does not degrade the internal
components
 TNB Integrated Learning Solution (ILSAS)
NiCd BATTERY INSTALLATIONS

Typically 87-88
cells per bank

Two-tier
Wooden Rack

Typically 87-88 cells

Typically 87-88
per bank
cells per bank
 TNB Integrated Learning Solution (ILSAS)

SEAL ACID BATTERY INSTALLATIONS

 TNB Integrated Learning Solution (ILSAS)

SITE ACCEPTANCE TEST REQUIREMENT FOR

BATTERY BANKS & DB BOARD
1. Complete charge and discharge test for all battery cells including the
spares
2. Discharge test shall be carried out for a minimum duration of 8 hours.
3. Specific gravity measurement shall be taken at the start and end of the
discharge test.
4. Voltage measurement for each cell shall be taken hourly during
discharge test.
5. Terminal connection tightness check. (Torque check – as per
recommended by manufacturer).
6. Check all battery cell, isolation fuse, distribution board, MCB are
labeled clearly.
7. Check that the Distribution Board is configured as per the single line
diagram and confirm labeling of all distribution MCB’s are in order by
test.
8. Open circuit voltage of the battery when it is fully charged shall be
measured and recorded.
 TNB Integrated Learning Solution (ILSAS)

CHARGER
 TNB Integrated Learning Solution (ILSAS)

BATTERY CHARGER
TNB Integrated Learning Solution (ILSAS)
 TNB Integrated Learning Solution (ILSAS)
BATTERY CHARGER
An isolating Then it will A filtering
transformer is used rectified by the network consisting
to isolate the mains S.C.R. (Silicon of inductors and
supply from the DC Controlled Full- capacitors are used
circuit. It also wave Rectifier) to smooth out the
change the mains bridge to obtain DC output to obtain
voltage to a DC output low output ripple
suitable level voltage.
 TNB Integrated Learning Solution (ILSAS)

BATTERY CHARGER
 TNB Integrated Learning Solution (ILSAS)

BATTERY CHARGER

OUTPUT VOLTAGE

The nominal float charge voltage shall be 110%

(121Volt) of the nominal system voltage.

Minimum range of charger output voltage

adjustments:

Float =100% to 125% of nominal voltage

Boost =110% to 140% of nominal voltage
 TNB Integrated Learning Solution (ILSAS)

ALARMS & INDICATIONS

INDICATIONS
AC Mains ON
Charger fail (red)
Charger on Automatic Float (white)
Charger on Manual Float (white)
Charger on Automatic Boost (orange)
Charger on Manual Boost (orange)
Charger on fast charge for commissioning
DC earth fault
Battery low-electrolyte level
Battery low-voltage
Battery over-voltage
 TNB Integrated Learning Solution (ILSAS)
ALARMS & INDICATIONS

INDICATIONS
Voltmeter
Charger output DC voltage
Charger input AC voltage
Battery output DC voltage
Ammeter
Charger output DC current
Load output DC current (center zero ammeter)
Battery charge /discharge current (center zero
ammeter)
Selector switch Float/Boost selection
MCB.
Mains ON/OFF input
 TNB Integrated Learning Solution (ILSAS)

ALARMS & INDICATIONS

ALARM FACILITIES

Self-reset alarms

• Mains failure
• Charger fail
• Battery earth fault
• Low electrolyte level
• Battery under-voltage
• Battery over-voltage
 TNB Integrated Learning Solution (ILSAS)

SITE ACCEPTANCE TEST REQUIREMENT FOR DC CHARGER

• Preferably commissioning of the battery charger shall be
performed by the charger manufacturer
• The Charger shall be commissioned first before being
connected to the batteries
• SAT tests
1. Boost interlocking scheme
2. Float voltage setting
3. Boost voltage setting
4. Boost charging current
5. High voltage alarm setting
6. Low voltage alarm setting
7. A/C fail condition
8. Charger fail condition
9. Low electrolyte level alarm
10. DC earth fault – positive and negative
11. Transducer (if available)
 TNB Integrated Learning Solution (ILSAS)

THANK YOU