Battery Charger Sizing Guide

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
277266699.xls (Index)
DETERMINATION OF RATING OF BATTERY CHARGER
Page 1 of 17
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 Vendors 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.
277266699.xls (General)
Page 2 of 17
ith respect to
per standard
rent has been
aging factor, the
277266699.xls (General)
Page 3 of 17
6.0 BATTERY LOAD CYCLE
Sl.
No.
Load
Description
Turbine Auxiliaries
Emergency Oil Pump (12 kW)
Generator
Generator Excitation
System(Assumed)
Generator Protection Panel (Assumed)
CO2 System
11 kV Switchgear
Spring charging motor of 11 kV
Breaker
( 250 W)
1
2
Closing coil of 11 kV Breaker (250 W)
Tripping of 11 kV Breaker ( 500 W)
4
D
1
Control supply, indication circuit and

protective relays for 15 nos breakers
@ 0.3 A each for 11 kV switchgear
6.6 kV Station Switchgear
Spring charging motor of 6.6 kV
Breaker
( 220 W)
Closing coil of 6.6 kV Breaker (440 W)
Tripping of 6.6 kV Breaker (440 W)
4
E
1

protective relays for 8 nos breakers @
0.3 A each for 6.6 kV switchgear
415 V Station Switchgear
Spring charging motor of 415 V
Breaker ( 220 W)
Closing coil of 415 V Breaker (110 W)
Tripping of 415 V Breaker (110 W)

protective relays for 18 nos breakers
@ 0.3 A each for 415 V switchgear
415 V Boiler MCC#1

Spring charging motor of 415V
Breaker
(200 W)

0.3 A each for 415 V switchgear
415 V Boiler MCC#2

Breaker
(200 W)

415 V Boiler MCC#3
277266699.xls (LoadCycle)
BATTERY LOAD CYCLE: 220V DC BATTERY

No. of
From
To
From
Total Simultaneou
0
1
1
Nos.
s
Operation Minute load (A) Minute load (A)
Type
of
Load
Unit
Load
(A)
Continuou
s
64.17
256.68
128.34
1.00
2.00
2.00
1.00
2.00
2.00
2.00
4.00
4.00
1.14
15
1.14
15
2.27
15
15
34.09
0.30
15
15
4.50
1.00
2.00
2.00
12.00
0.30
2.40
1.00
18
0.50
18
0.50
18
13
6.50
0.30
18
18
5.40
0.91
0.50
0.50
1.00
0.30
0.90
0.91
0.50
0.50
1.00
0.30
0.90
Continuou
s
Continuou
s
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
4.50
2.40
5.40
0.90
0.90
Page 4 of 17
Sl.
No.
Load
Description

Breaker
(200 W)

415 V Water MCC

Breaker
(200 W)

415 V ESP MCC

Breaker
(200 W)

415 V Ash Handling MCC

Breaker
(200 W)

415 V STG MCC#1

Breaker
(200 W)

415 V STG MCC#2

Breaker
(200 W)

415 V BOP MCC
Type
of
Load
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Momentar
y
Momentar
y
Momentar
y
Continuou
s

No. of
From
To
From
Total Simultaneou
0
1
1
Nos.
s
Minute
load
(A)
Minute
load (A)
Operation
Unit
Load
(A)
0.91
0.50
0.50
1.00
0.30
0.90
0.91
0.50
0.50
0.50
0.30
0.60
0.91
0.50
0.50
0.50
0.30
0.60
0.91
0.50
0.50
0.50
0.30
0.60
0.91
0.50
0.50
1.00
0.30
0.90
0.91
0.50
0.50
1.00
0.30
0.90
0.90
0.60
0.60
0.60
0.90
0.90
Page 5 of 17
Sl.
No.
Load
Description

Breaker
(200 W)

Intercommunication
Emergency Lighting
Miscellaneous Loads
Total load in Amps.
Type
of
Load
Momentar
y
Momentar
y
Momentar
y
Continuou
s
Continuou
s
Continuou
s
Continuou
s

No. of
From
To
From
Total Simultaneou
0
1
1
Nos.
s
Minute
load
(A)
Minute
load (A)
Operation
Unit
Load
(A)
0.91
0.50
0.50
0.50
0.30
0.60
0.60
5.00
5.00
5.00
20.00
20.00
20.00
10.00
10.00
10.00
378.48
190.54
Page 6 of 17
TERY
To
59
From
59
To
60
Continuous
Load (A)
Remarks
Minute load (A) Minute load (A)

128.34
128.34
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
Page 7 of 17
TERY
To
59
From
59
To
60
Continuous
Load (A)
Remarks

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
Page 8 of 17
TERY
To
59
From
59
To
60
Continuous
Load (A)
Remarks

0.91
0.50
0.60
0.60
0.60
5.00
5.00
5.00
20.00
20.00
10.00
10.00
190.54
210.00
32.20
Page 9 of 17
time
CURRENT IN AMP
0
0
1
1400
59
59
60350
60
0
0300
0
0
0250
0
0
0200
current
0
378.4754
378.4754
190.5422
190.5422
209.9968
209.9968
0
0
0
0
0
0
0
0
0
SEC : 7 -BATTERY LOAD CYCLE
150
100
50
0
0
20
40
60
80
TIME IN MIN
277266699.xls (Loadcurve)
Page 10 of 17
LE
60
277266699.xls (Loadcurve)
80
Page 11 of 17
8.0
DETERMINATION OF NUMBER OF CELLS

Nominal cell voltage
2 volts
Nominal battery voltage
220 volts
Float voltage
2.15 volts
End cell voltage
1.85 volts
System DC voltage variation
Boost voltage
(as per reputed manufacturer's catalogue)
220V, + 10% to - 15%
242.00 volts to
2.75 volts
187.00
volts
Number of cells determined considering the minimum system voltage and end cell voltage =
Minimum System Voltage
End Cell Voltage
=187/1.85 =
101.08
..(i)
Number of cells determined considering the maximum system voltage and float voltage =
Maximum System Voltage
Float Charging Voltage
=242/2.15=
112.56 ..(ii)
Number of cells chosen is lower of the values as per eq (i) & (ii) =
###
=
102
Taken
Maximum system voltage considering 102 cells and float voltage of 2.15 volts =
102 x 2.15
=
<
219.3
242.00
volts
volts
Minimum system voltage considering 102 cells and end cell voltage of 1.85 volts =
102 x 1.85
=
>
188.7
187.00
volts
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 =
Minimimum site/ electrolyte temperature in deg C =
% change of capacity on discharge with temperature for PLANTE' type battery
Temperature correction factor = 1 + 0.9/100(27-5) =
277266699.xls (Cell)
27
5
0.9
1.198
Page 12 of 17
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
277266699.xls (Cell)
Page 13 of 17
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 =
378.5
Amp
A2 =
190.5
Amp
A3 =
210.0
Amp
[1]
[2]
[3]
[4]
[5]
[6]
Period
Load
Change in
Load
Duration Of
Period
Time End of Section
Capacity Factor
at t Min. rate (KT)
Section 1: First Period Only - if A2 is greater than A1, go to Section 2

1 A1=
378.5
378.5 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=
378.5
378.5 M1= 1
t= M1 + M2 =59
2 A2=
190.5
-187.9 M2 = 58
t= M2 = 58
1.897
1.893
Section 2
Section 3 : First Three Periods Only - if A4 is greater than A3, go to Section 4

1 A1=
378.5
378.5 M1 = 1
t= M1 + M2 + M3 = 60
2 A2=
190.5
-187.9 M2 = 58
t=M2 + M3 = 59
3 A3=
210.0
19.5 M3 = 1
t = M3 = 1
1.900
1.897
1.250
Section 3
Uncorrected Cell Size = Maximum Section Size =

Design Margin =
Aging Factor =
566.8
10%
1.00
623.4
Cell Size (Uncorrected Cell Size) * (Design Margin) * (Aging Factor) =

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 I 1 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)
128.34
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
277266699.xls (Charger)
Page 14 of 17
I1 =
40.25 + [ 1.1 x 645 /8 ] =
128.94
(Amp)
From eq. No. (1),
I2 =
40.25 +128.342 =
168.59
(Amp)
From eq. No. (2),
I3 = Recommended charger out put, larger of I 1 or I2 =
168.59
(Amp)
Charger Rating Selected at 220 V DC
175 Amp
Page 15 of 17
[7]
[8]
Temp Derating
Factor for t Min. (Tt)
Required Section Size =

(3)x(6)x(7) = Rated AH.
Pos. Values
Neg. Values
1.198
Total (AH)
566.8
566.8
1.198
1.198
Sub. Total
Total (AH)
1.198
1.198
1.198
Sub. Total
Total
861.5
-427.1
29.1
890.6
463.5
-427.1
AH
Considering 25% design margin
(Assumed)
Page 16 of 17
Page 17 of 17

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Battery and Charger Sizing

CODES & STANDARDS

BATTERY LOAD CYCLE

BATTERY LOAD CURVE

DETERMINATION OF NO. OF CELLS

DETERMINATION OF AH RATING OF BATTERY

DETERMINATION OF RATING OF BATTERY CHARGER

Battery and Charger Sizing

Battery and Charger Sizing

rent has been

aging factor, the

Battery and Charger Sizing

6.0 BATTERY LOAD CYCLE

Emergency Oil Pump (12 kW)

Closing coil of 11 kV Breaker (250 W)

Tripping of 11 kV Breaker ( 500 W)

Control supply, indication circuit and

Closing coil of 6.6 kV Breaker (440 W)

Tripping of 6.6 kV Breaker (440 W)

Control supply, indication circuit and

Closing coil of 415 V Breaker (110 W)

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V Boiler MCC#1

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V Boiler MCC#2

Spring charging motor of 415V

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V Boiler MCC#3

BATTERY LOAD CYCLE: 220V DC BATTERY

Battery and Charger Sizing

Spring charging motor of 415V

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V Water MCC

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V ESP MCC

Spring charging motor of 415V

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V Ash Handling MCC

Spring charging motor of 415V

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V STG MCC#1

Spring charging motor of 415V

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V STG MCC#2

Spring charging motor of 415V

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

415 V BOP MCC

BATTERY LOAD CYCLE: 220V DC BATTERY

Battery and Charger Sizing

Spring charging motor of 415V

Tripping of 415 V Breaker (110 W)

Control supply, indication circuit and

Total load in Amps.

BATTERY LOAD CYCLE: 220V DC BATTERY