DC and Ups System Capacity Planning and Design

MODULE - 19
DC AND UPS SYSTEM CAPACITY PLANNING AND

DESIGN OF THE POWER BLOCK AREA
PUBLIC INTERNAL RESTRICTED CONFIDENTIAL

1
CONTENT
Part 1 Introduction
Part 2 General Definition
Part 3 Design Condition
Part 4 Capacity Planning
Part 5 Sizing Calculation
DC AND UPS SYSTEM CAPACITY PLANNING AND DESIGN OF THE POWER BLOCK AREA 2
Introduction
- DC System: DC system (Battery, Battery Charger) delivers power to DC loads i.e., as switchgear, protection,
emergency lighting, DC drives, UPS loads etc. There are two separate DC Systems in this project.
• 125 V DC System for Main Control Building (MCB)
• 125V DC System for STG (ST-7)
• The DC system consist of one (1) set of Valve Regulated Lead-Acid Battery with two (2) sets of Battery Charger
and necessary DC Distribution Panel.
- UPS System: It delivers power to critical loads like computer terminals, servers, process control systems (e.g.,
DCDAS or PLC), telecommunication equipment, display device and sensitive electronic equipment. There are two
separate UPS Systems in this project.
• 120 V AC Uninterruptable Power Supply System (UPS) for Main Control Building.
• 120 V AC Uninterruptable Power Supply System (UPS) for STG (ST-7).
• The Uninterruptable Power Supply System consist of two (2) sets of inverters, and one (1) common manual bypass
for both inverters and AC Distribution Panel. DC source for inverters is connected to respective area 125 V DC
system.
Introduction
 125V DC System for STG 125 V DC System for Main Control Building
Introduction
- Battery Charger and Battery Operation in normal Mode:
• Float Mode: AC supply is available, and the following conditions are satisfied.
 Battery is in fully Charged Condition and gets trickle charging current (in mA) from Battery Charger to
compensate its internal loss.
 DC Loads get power from Battery Charger (not Battery).
 Momentary excess load (any motor starting which is beyond the battery charger capacity) shall be supplied by
the battery.
• Boost Mode: AC supply is available after restoration (black out) and the following conditions are satisfied.
 Battery gets charging current (constant current charging) from Battery Charger to build up voltage.
 DC Loads get power from Battery Charger (not Battery).
 Momentary excess load shall be supplied by the battery. It should be avoided in Boost Mode to charge the
battery faster.
Introduction
FLOAT MODE
Introduction
FLOAT MODE
Introduction
BOOST MODE
Introduction
CHARGER FAIL MODE
Introduction
Introduction
 120V UPS System for STG 120V UPS System for Main Control Building
 Input side of both the systems shall be connected to corresponding DC system

Introduction
Introduction
Introduction
1 AC supply for bypass (multicoloured)

2 BY-PASS (multicoloured)
3 DC supply/battery (multicoloured)
4 Inverter (multicoloured)
5 Manual BY-PASS (green)
6 Load output (green)
Introduction
- The color and the lighting/flashing of the LEDs give information on the current operating state:
• Green-yellow flashing: Starting phase
• Green flashing: Pre charge ok
• Green glowing: Operating.
• Yellow flashing: Warning
• Yellow glowing: Available (ready for switch-on)
• Red flashing: fault
• Red glowing: Abnormal state (mains error)
- For Power Flow through Inverters during different modes, please refer to the attached Annexure-A.
- Switching on of Inverter:
• Press BYPASS key briefly once on one unit.
• Check if LED 1 & 2 (green) and LED 3 (yellow), in the mimic diagram glow continuously.
Introduction
• Press the key I on the operating panel. The charging process for the intermediate circuit begins. During the pre-
charge, LED 3 flashes green-yellow. When the preliminary charge voltage is achieved the green-yellow flashing
turns into a green flashing. After approx. 10 sec. the following prompt is displayed on the operating panel.
• Close the breaker available in Inverter Input side.
• LED 3 also flashes green to indicate that the preliminary charge voltage has been achieved. Now the inverter
circuit is charged, and bypass mode is in operation.
• To start the inverter, press key I again. During the starting process of the inverter, LED 4 flashes green-yellow.
After the starting process, the unit is in the state "Inverter-STANDBY"; LED 4 is green, now.
• Now press key I again. The unit passes into the state "Inverter operation". The LEDs 3, 4 and 6 light up green
and the inverter now feeds the load.
- Switching off Inverter:
• Press “BYPASS” key.
• Press “O” key once on each unit for a longer time. The LEDs 1, 2 and 3 light up green. LED 6 flashes green.
Introduction
• Open circuit breaker of both the Inverter.
• Switch off all by-passes (press O key on each unit twice for a longer time).
• Completely disconnect the inverters.
- Switching on the manual service BY-PASS :
• Close Circuit Breakers (MCCB) bypassing the Static Unit.
• Press key "O" for longer time.
• Open Inverter “Input side Circuit Breaker”- This message will be displayed.
• Press key "O" for longer time until a bleep signal is heard.
• The following confirmation request then appears in the display of the operating panel for approx. 10 sec.
Switch off BY-PASS? (Static)
Yes -> Press key again!
Introduction
• This request must be confirmed within 10 sec. by pressing the key “O” again for longer until a signal beep is
heard. Now the system is shut down and manual bypass is closed. If another key or no key is pressed during
this time, the request disappears from the display and the process is aborted.
• Open Inverter “Input side Circuit Breaker”.
- Reference Standards
• IEEE 485, Recommended Practice for Sizing Lead-Acid Batteries for Stationary Applications.
• IEEE 946, Recommended Practice for the Design of DC Auxiliary Power Systems for Generating Stations.
• Project Specific Document.
General Definition
- Battery: It is a combination of cells, connected in series. - Battery Charger: It converts AC power to DC power
Ampere-hour (AH) capacity of each cell is same as and supply the same to DC load and battery.
battery (series relation). Voltage of the battery is the
summation of voltage of cells.
General Definition
- DC Load requirement of the Plant in case of failure of AC supply- Battery is discharging (No Battery Charger is
working).
General Definition
- Battery Duty Cycle: DC Load Requirement is segregated into different sections based on different load current
and different time periods. Load current throughout the section (each section) shall be same.
It is used in Battery Capacity determination.
General Definition
- General considerations for Battery Sizing: The battery supplies the DC power requirements in the following
conditions:
• Load on the DC system exceeds the maximum output of the battery charger.
• Output of the battery charger is interrupted.
• AC power is lost (Outage of total utility power and EDG source lost in power plant). This will be the most severe of
above conditions, in terms of battery load and duration, should be used to determine the battery size for the
installation.
General Definition
General Definition
- Voltage at Float Mode: Constant Voltage operation: Battery Charger Voltage remains constant as per set value
• Condition-1: Required voltage for Battery in float mode: 2.25 V per cell * 58 (number of cell) = 130.5 V
• Condition-2: Permissible voltage range for DC Loads: 90 V (min) to 140 V (max).
If Condition-1 is fulfilled (set the battery charger voltage at 130.5 V), then Condition-2 will be satisfied.
- Voltage at Boost (Equalizing) Mode: Constant Current operation: Battery Charger Current remains constant as
per set value
• Condition-1: Required voltage for Battery in Boost (Equalizing Mode) mode: 2.4 V per cell * 58 (number of
voltage) = 139.2 V
• Condition-2: Permissible voltage range for DC Loads: 90 V (min) to 140 V (max).
If Condition-1 is fulfilled (set the battery charger voltage at 139.2 V), then Condition-2 will be satisfied.
General Definition
Battery Charging Curve
General Definition
Battery Capacity: The rated ampere hour (AH) capacity.

AH capacity of Cell = AH Capacity of the Battery (collection of Cell)
Valve-regulated lead-acid (VRLA) cell: A lead-acid cell that is sealed except for a valve that opens to the
atmosphere when the internal gas pressure in the cell exceeds atmospheric pressure by a pre-selected amount.
End Cell Voltage: Minimum voltage of a cell. Battery operation (discharge) below this voltage is not
recommended.
Temperature Correction Factor: The available capacity of a cell is affected by its operating temperature. Battery
manufacturer provides rated AH capacity of a cell/battery in the standard electrolyte temperature (25 °C). If
the operating electrolyte temperature increases, the cell/battery will deliver higher capacity from its rated
capacity. Similarly, if the operating electrolyte temperature is below this standard temperature, the battery
will deliver lower capacity than its rated capacity. Battery manufacturer provides a table or curve or formula for
Temperature Correction Factor with respect to electrolyte temperature.
• Temperature correction factor of minimum site ambient to be applied to get higher Ah capacity during sizing.
• Battery kept in AC room: Temperature correction factor to be taken according maintained temperature of AC room.
• Electrolyte temperature can be considered higher than ambient temperature if manufacture recommends.
General Definition
Temperature Correction Factor For Project Specific Battery
General Definition
• Electrolyte temperature will not fall below minimum electrolyte temperature, specified by manufacturer (when
battery is in service) if ambient temperature falls below minimum electrolyte temperature.
For example, if battery remains in service condition with electrolyte temperature 15 °C and the ambient
temperature is lower than 15 °C, then battery electrolyte temperature shall remain at 15 °C.
- Battery Life: The battery shall have a life expectancy (in terms of certain years) at specified condition
(temperature, operating condition). Battery Life is 20 years in this project.
 Capacity Rating Factor: Battery capacity is expressed as AH (current * Time) capacity. For an example, if a
battery has 500 AH capacity, theoretically it should deliver 500 A for one hour or 250 A for two hour. But practically,
it can not occur.
Why?
Reason:
Battery voltage gradually deceases due to current discharge. Initially discharge current shall be high. Later, battery
discharge current becomes less due to decrease of battery voltage.
How much current for a specified time can be discharged from a particular battery? It is decided by
Capacity Rating Factor.
General Definition
There are two terms to express capacity rating factors:
• Kt factor : Rated ampere hour of battery/ desired ampere for specified time (derived from manufacturer data or
curve)
• Rt factor: Amps available for specified time per positive plate of cell (derived from manufacturer data or curve).
ECV: End Cell Voltage of Battery.
General Definition
General Definition
- Aging factor: As a rule, the performance of a lead-acid battery is relatively stable throughout most of its life but
begins to decline with time. IEEE Std 450-1995 recommends that a battery be replaced when its actual
performance drops to 80% of its rated performance because there is little life to be gained by allowing operation
beyond this point. Therefore, to ensure that the battery can meet its design loads throughout its service life, the
battery’s rated capacity should be at least 125% (1.25 aging factor) of the load expected at the end of its service
life.
Exceptions to this rule exist. For example, some manufacturers recommend that vented batteries with Plante,
modiﬁed Plante, and round plate designs be replaced when their measured capacity drops below 100% of their
rated capacity (1.00 aging factor). These designs maintain a constant capacity throughout their life.
Design margin: It is prudent to provide a capacity margin to allow for unforeseen additions to the DC system,
improper battery maintenance, recent discharge, or ambient temperatures lower than anticipated, or a
combination of these factors. In this project 20% design margin has been considered.
Design Condition
- Following parameters are considered for sizing of battery, charger and UPS in this project.
• Battery Charger:
 Input Voltage : 480V AC,3 Phase, 60Hz
 Output Voltage : 125 V DC
 Capacity for Charger : 2X100% - Two chargers having 100% capacity (full DC load meeting capacity) [i.e. in
case of failure of one charger, another will meet the entire DC load demand)
• Battery:
 Nominal Voltage : 125 V DC.
 DC System Voltage Variation : 105 V DC (minimum) – 139.2 V DC (maximum)
 Design margin : 20%
 Battery design temperature : 25 °C minimum.
Design Condition
 Battery backup time : 8 hours.
 Boost (Equalize) Charging Voltage : 2.40 V/cell.
 Floating charging voltage : 2.25 V/cell.
 End Voltage : 1.81 V/cell
• Uninterrupted Power Supply (UPS/ Inverter):
 Input Voltage to Inverter: 125 V DC.
 Output Voltage: 120 V AC (Single Phase)
 Nominal Voltage to Bypass: 480V AC,3 Phase, 60Hz.
 Voltage window of battery : 105 V DC – 139.2 V DC.
 Design margin on UPS: 30%
Planning
• DC Load Details in Each Electrical Equipment: Annexure-B.
• DC Load Details in STG (ST-7) : Annexure-C.
• DC Load Details in MCB: : Annexure-D.
• UPS Load Details in STG (ST-7): Annexure-E.
• UPS Load Details in MCB: : Annexure-F.
Sizing Calculation: UPS
• Sizing Calculation for ST-7 UPS:
- Total Load Current Demand: 444.9 A.
- Design Margin (Spare Capacity): 30%.
- Calculated Output Current: 1.3*444.9 = 578.3 A
- Output KVA: 120*578.3 A = 69.396 kVA
Selected UPS Total KVA : 100 KVA (50 KVA + 50 KVA) ( Make: Benning, Model: Invertronic)
• Sizing Calculation for MCB UPS:
- Total Load Current Demand: 137.7 A.
- Design Margin (Spare Capacity): 30%.
- Calculated Output Current: 1.3*137.7 = 179 A
- Output KVA: 120*179 A = 21.48 kVA
- Selected UPS Total KVA : 52 KVA (26 kVA + 26 kVA) ( Make: Benning, Model: Invertronic)
Sizing Calculation: Battery Charger
Battery charger ratings are calculated based on the continuous DC loads.

• Rating of battery charger is calculated with reference to equation given in IEEE std. 946.
I1= Lc + 1.1 x Ah/ T Charger size of MCB DC System
where,
I1 = Minimum required charger rated output in amperes

Lc = is the continuous dc load (in amperes), including future load growth
1.1 = is the constant that compensates for the battery losses
Ah = is the ampere-hours discharged from the battery. It is recommended that the 8 h ampere-
hour rating of the battery be used in this formula for any duty cycle with an overall duration of 8
h or less. For longer duty cycles, use the battery rating corresponding to the overall duration.
T = is the time to recharge the battery to approximately 95% of capacity (in hours). To minimize
dc system downtime, a reasonable recharge time should be selected; 8-12 h is recommended.
Sizing Calculation: Battery Charger
ST-7 Battery Charger:
• Lc = 676.9 A (Continuous Load)
• Ah: 7065
• T = 12 hours
• Required Output Current = 676.9 + 1.1*7065 / 12 = 1324.52 A
• Selected Rating: 1430 A ( Make: Benning, Model: Thyrotronic)
MCB Battery Charger:
• Lc = 153.3 A (Continuous Load)
• Ah: 3140
• T = 12 hours
• Required Output Current = 153.3 + 1.1*3140/12 = 441.13 A
• Selected Rating: 550 A ( Make: Benning, Model: Thyrotronic)
Sizing Calculation: Battery- Number of Cell
- This Calculation is done as per IEEE-485.
- The battery voltage is not allowed to exceed a given maximum system voltage in this project because battery is
connected to DCDB in Boost charging (Equalizing Charging) mode.
No. of cells w.r.t. maximum voltage = Max. allowable system voltage / Boost (Equalizing Voltage)
= 139.2/2.4
= 58
- The minimum battery voltage equals the minimum system voltage at DCDB plus cable (connected between DCDB
and battery) voltage drop . The minimum battery voltage is used to calculate the End Cell Voltage (ECV).
End Cell Voltage (ECV) = Minimum system voltage / Number of Cell = 105/58 = 1.81 V
ECV is the most important factor for Battery.
Sizing Calculation: ST-7 DC System Battery AH Capacity Determination
- Sizing Calculation is done as per IEEE-485
• First Step: Determination of Battery Duty Cycle
- 1st Period (from 0 to 1 minute): 825.7 A (A1)
- 2nd Period (from 1 to 10 minute): 676.9 A (A2)
- 3rd Period (from 10 to 60 minute): 631.4 A (A3)
- 4th Period (from 60 to 120 minute): 631.4 A (A4)
• Second Step: Determination of AH capacity for 1st Period.
 Change in Load: A1-0 = 825.7 A (at the time when battery discharging starts, current is zero).
 Time to end section = 1 min.
 Capacity rating factor of battery for the above load current and duration: 1.77
 Required Capacity for this period = 825.7*1.77 = 1464.85 AH
• Third Step: Determination of AH capacity for First Two Period (1st period and 2nd Period).
 Part-1:
Change in Load: A1-0 = 825.7 A.
Time to end section = 10 min.
Capacity rating factor of battery for the above load current and duration: 1.77.
Required Capacity for this period = 825.7*1.77 = 1464.85 AH
 Part-2:
Change in Load: A2-A1 = 676.9 – 825.7 = - 148.8 A.
Required Capacity for this period = - 148.8*1.77 = - 263.98 AH.
Required Capacity for First Two Period: 1464.85 – 267.98 = 1200.87 AH.
• Fourth Step: Determination of AH capacity for First Three Period (1st period, 2nd Period and 3rd Period).
 Part-1:
 Part-2:
Required Capacity for this period = - 148.8*2.56 = - 380.39 AH
 Part-3:
Required Capacity for First Three Period: 2125.77 – 380.39 – 108.97 = 1636.31 AH
• Fifth Step: Determination of AH capacity for First Four Period (1st period, 2nd Period, 3rd Period and 4th
Period).
 Part-1:
 Part-2:
Required Capacity for this period = - 148.8 * 3.54 = - 526.59 AH

 Part-3:
 Part-4:
Change in Load: A4-A3 = 631.4 – 631.4 = 0A.
Required Capacity for this period = 0 AH
Required Capacity for First Four Period: 2935.57 – 526.59 – 154.33 - 0 = 2254.66 AH
• Sixth Step: Determination of AH capacity for First Five Period (1st period, 2nd Period, 3rd Period, 4th Period
and 5th Period).
 Part-1:
 Part-2:

 Part-3:
Capacity rating factor of battery for the above load current and duration: 8.41 .
 Part-4:
 Part-5:
Required Capacity for this period = - 1895.97 AH
Required Capacity for First Five Period: 7048.22 – 1268.27 – 382.61 – 1895.97 = 3501.37 AH
• Seventh Step: Determination of AH capacity for First Six Period (1st period, 2nd Period, 3rd Period, 4th
Period, 5th Period and 6th Period).
 Part-1:
 Part-2:

 Part-3:
 Part-4:
 Part-5:
Required Capacity for this period = - 1899.58 AH
 Part-6:
Change in Load: A6-A5 = 553.6 – 359.3 = 194.3 A.
Required Capacity for this period = 194.3 * 1.77 = 344.7 AH
Required Capacity for First Six Period: 7058.71 – 1270.16 – 383.19 – 1899.58 + 344.7 = 3850.48 AH
Required minimum capacity in Ah = USⅹTCⅹDMⅹAF
• US – Maximum AH [Ah]
• TC - The Temperature Correction Factor
• DM - The Design Margin
• AF- The Aging Factor
Required Capacity = 3850.48 * 1 * 1.2 * 1.25 = 5775.72 AH
Battery Make: Hoppecke
Selected AH size for VRLA Battery (Make: Hoppecke, Model: Gridpower) : 2360 AH
Hence three number of battery string (58 cell in one string) of 2360 AH capacity (3*2360 = 7080) are used.
Refer to attached Annexure-G for Battery Sizing Calculation, done by manufacturer.
Sizing Calculation: MCB DC System Battery AH Capacity Determination
For MCB DC System Battery AH Capacity Determination, refer to the same concept described in the previous slides.
Required minimum capacity in Ah = USⅹTCⅹDMⅹAF
• US – Maximum AH [Ah]
• TC - The Temperature Correction Factor
• DM - The Design Margin
• AF- The Aging Factor
Required Capacity = 1411.38 * 1 * 1.2 * 1.25 = 2117.07 AH
Battery Make: Hoppecke
Selected AH size for VRLA Battery (Make: Hoppecke, Model: Gridpower) : 3140 AH
Refer to attached Annexure-H for Battery Sizing Calculation, done by manufacturer.
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MODULE - 19

DC AND UPS SYSTEM CAPACITY PLANNING AND

PUBLIC INTERNAL RESTRICTED CONFIDENTIAL

Part 2 General Definition

Part 3 Design Condition

Part 4 Capacity Planning

Part 5 Sizing Calculation

• 125 V DC System for Main Control Building (MCB)

• 125V DC System for STG (ST-7)

• 120 V AC Uninterruptable Power Supply System (UPS) for STG (ST-7).

 DC Loads get power from Battery Charger (not Battery).

 DC Loads get power from Battery Charger (not Battery).

CHARGER FAIL MODE

 Input side of both the systems shall be connected to corresponding DC system

1 AC supply for bypass (multicoloured)

• Green-yellow flashing: Starting phase

• Green flashing: Pre charge ok

• Green glowing: Operating.

• Yellow flashing: Warning

• Yellow glowing: Available (ready for switch-on)

• Red flashing: fault

• Red glowing: Abnormal state (mains error)

• Press BYPASS key briefly once on one unit.

• Close the breaker available in Inverter Input side.

- Switching off Inverter:

• Press “BYPASS” key.

• Completely disconnect the inverters.

- Switching on the manual service BY-PASS :

• Close Circuit Breakers (MCCB) bypassing the Static Unit.

• Press key "O" for longer time.

• Open Inverter “Input side Circuit Breaker”.

It is used in Battery Capacity determination.

• Output of the battery charger is interrupted.

• Condition-2: Permissible voltage range for DC Loads: 90 V (min) to 140 V (max).

• Condition-2: Permissible voltage range for DC Loads: 90 V (min) to 140 V (max).

Battery Charging Curve

Battery Capacity: The rated ampere hour (AH) capacity.

Temperature Correction Factor For Project Specific Battery

ECV: End Cell Voltage of Battery.

 Input Voltage : 480V AC,3 Phase, 60Hz

 Output Voltage : 125 V DC

 Nominal Voltage : 125 V DC.

 DC System Voltage Variation : 105 V DC (minimum) – 139.2 V DC (maximum)

 Design margin : 20%

 Battery design temperature : 25 °C minimum.

 Battery backup time : 8 hours.

 Boost (Equalize) Charging Voltage : 2.40 V/cell.

 Floating charging voltage : 2.25 V/cell.

 End Voltage : 1.81 V/cell

• Uninterrupted Power Supply (UPS/ Inverter):

 Input Voltage to Inverter: 125 V DC.

 Output Voltage: 120 V AC (Single Phase)

 Nominal Voltage to Bypass: 480V AC,3 Phase, 60Hz.

 Voltage window of battery : 105 V DC – 139.2 V DC.

 Design margin on UPS: 30%

• DC Load Details in Each Electrical Equipment: Annexure-B.

• DC Load Details in STG (ST-7) : Annexure-C.

• DC Load Details in MCB: : Annexure-D.

• UPS Load Details in STG (ST-7): Annexure-E.

• UPS Load Details in MCB: : Annexure-F.

- Total Load Current Demand: 444.9 A.

- Design Margin (Spare Capacity): 30%.