110V Battery & Battery Charger Sizing Calculation for

PHP INTEGRATED STEEL MILLS LTD.

 Project Name: 132/11KV, 30/35MVA SUB-STATION.

 Contractor: ENERGYPAC ENGINEERING LTD.

 Client: POWER GRID COMPANY of BANGLADESH

 CONTENTS

Page No.

1 INTRODUCTION 3

2 DESIGN CRITERIA FOR BATTERY SIZING 3

3 CALCULATION FOR NUMBER OF CELLS 4

4 DESIGN CRITERIA FOR BATTERY CHARGER SIZING 5

5 REFERENCES 5

6 ASSUMPTIONS 5

7 CALCULATION 6-13

i 110V DC LOAD DETAILS 6-7

ii LOAD SUMMARY 7
iii LOAD CYCLE TABLE & GRAPH 8
iv AH SIZING CALCULATION OF BATTERY & BATTERY CHARGER 9-12

8 RESULT 5

9 ANNEXURES:-

i DVR Calculation

ii UPS Sizing

iii K- factor curves (HBL)

iv Temperature correction factor (HBL)

1 INTRODUCTION:
DC Power Supply is the most reliable source of power supply for control, protection
interlock & annunciation requirements both during the AC power failure and in normal
operating conditions.

This document is intended to size the 110V Ni-Cd battery &

battery charger required for 132/11KV, 30/35MVA PHP Substation. The
battery is sized in accordance with the IEEE 1115-2000 .
110V DC Power supply will consist of two number 100% rated battery along
with two number of 100% rated dual float cum boost charger to charge above
batteries.

2 DESIGN CRITERIA FOR BATTERY SIZING:

The duty cycle of battery is selected to be 5 hours. The battery shall be capable
of ,

i Two closing operations on all circuit breakers (including future) supplied by

the battery.

ii Two tripping operations on all circuit breakers (including future) supplied by the
battery. Where busbar protection is provided, it shall be assumed that all circuit
breakers in any one busbar protection zone trip simultaneously.

iii Charging of DC motor wound circuit breaker closing springs to enable the closing
operations is considered.

iv Battery can supply load at discharge rate of 10 hours without terminal voltage
drop from rated voltage.

v margin of 10% is considered for de-rating of the battery.

Accordingly, the load cycle is divided into six sections:

The section, corresponding time Ƭ considered load are as follows :

Section Number Time Period Load Considered

Momentary Tripping load +Continuous load +
Section - 1 0-1 min.
Emergency loads
Momentary Closing load +Continuous load +
Section - 2 1-2 min.
Emergency loads
Section - 3 2-60 min. Continuous load +Emergency loads
Section - 4 60 -298 min. Continuous load
Section - 5 298 -299 min Momentary Tripping load+ Continuous load
Section - 6 299 -300 min Momentary Closing load+ Continuous load

The minimum temperature is 4 °C

design margin of 10% and Ageing Factor of 15% is considered
on calculated size.

Page-3
3 CALCULATION FOR NUMBER OF CELLS

Nominal Voltage of the system = 110 V

Maximum Allowable system voltage percentage = +10 %

Maximum allowable system voltage = 121 V

Minimum allowable system voltage = -20 %

Minimum allowable system voltage = 88 V

End cell voltage = 1.0 V

Float charging voltage = 1.42 V

Maximum allowable system voltage

No. of cells (Cell) required =
cell voltage required for float charging

= 121 / 1.42
= 85.2

Minimum No. of cells required = 86.00

No. of cells selected = 92.00

Minimum battery voltage at the end of load cycle α No. of cells End cell Voltage

= 92×1.0
= 92 V
Which is higher than the minimum allowable system voltage

Hence, the number of cells selected as 92 is justified.

Page-4
4 DESIGN CRITERIA FOR BATTERY CHARGER SIZING

The battery charger is sized based on two numbers of applications envisaged.

i Under normal float charge conditions (with AC supply available), the battery
charger will cater to the continuous load of the DC system plus trickle charging
of the battery. It shall be possible to switch either charger out of service leaving
the remainder charger & batteries to carry the full DC load requirement & the
same time provide the full battery float charge requirement of the associated
battery.
ii The batteries may require boost charging from time to time, depending upon the
service conditions & other external forces. Under boost charge condition the
charger shall be capable of supplying full boost charge requirement, taking care
not to exceed the maximum permissible battery voltage & simultaneously cater
to the continuous load requirement of the DC system.

The higher of the two ratings (float charging condition & boost charging cond
-itions calculated as above) will be considered for rating the charger

5 REFERENCES
1. Project contract documents & Specification
2. IEEE 1115-2000
3. 132kV AIS Key SLD
4. Manufacturer published catalogues of various relays
5. Battery Catalouge

6 ASSUMPTIONS

i The calculation is performed based on published data for HBL NCPP Battery
Technical Manual

ii Total Emergency lighting load is considered 600 W.

iii DC Load details are considered based on our standard 132kV AIS product

7 CALCULATIONS

i 110V DC Load details

ii Load summary
iii Load cycle table & Graph
iv AH Sizing calculation of Battery & Battery Charger

8 RESULTS
i 110V Battery Size Selected 461 AH
ii Charger Selected 105 A

Page-5
 Table -1

POWER POWER Fire fighting

BATTERY No of Co Continuous Closing Tripping Emergency
EQUIPMENT CONSUMPTION LOCATION & NO. NO. CONSUMPTION equipment Motor REMARKS
VOLTAGE Panels efficient Load Peak peak Lighting
(Watt) (Watt) peak

Emergency
30 Control room building 20 600 1 0 0 0 0 0 600
Light

Annunciator 10 1 40 1 40 0 0 0 0 0
Indicator 2 8 64 1 64 0 0 0 0 0
Auxiliary 132KV Line feeder control
1 10 4 40 1 40 0 0 0 0 0
relay panel

Meter 5 6 120 1 120 0 0 0 0 0

P141 11 1 44 1 44 0 0 0 0 0
P442 11 1 44 1 44 0 0 0 0 0
P743 16 132KV Line feeder relay 1 64 1 64 0 0 0 0 0
4
TCS 15 panel 2 120 1 120 0 0 0 0 0
MVAJ 150 2 1200 1 0 0 0 1200 0 0

Annunciator 10 1 20 1 20 0 0 0 0 0
Indicator 2 7 28 1 28 0 0 0 0 0
132KV Transformer feeder
Auxiliary 2
1 control panel 10 20 1 20 0 0 0 0 0
relay
Meter 5 6 60 1 60 0 0 0 0 0

P642 16 2 64 1 44 0 0 0 0 0
TCS 15 132KV Transformer feeder 2 60 1 120 0 0 0 0 0
2
relay panel
MVAJ 150 2 600 1 0 0 0 600 0 0

Annunciator 10 1 10 1 10 0 0 0 0 0
Indicator 2 8 16 1 16 0 0 0 0 0
Meter 5 Bus Coupler control panel 5 1 25 1 25 0 0 0 0 0
Auxiliary
5 1 5 1 5 0 0 0 0 0
relay 110V

P741 16 1 16 1 16 0 0 0 0 0
P143 12 1 12 1 12 0 0 0 0 0
P743 16 Bus Coupler relay panel 2 1 32 1 32 0 0 0 0 0
TCS 15 2 30 1 30 0 0 0 0 0
MVAJ 150 2 300 1 0 0 0 300 0 0

P143 12 1 24 1 10 0 0 0 0 0
Meter 5 5 50 1 50 0 0 0 0 0
Auxiliary
1 11KV Incoming feeder 10 2 20 1 20 0 0 0 0 0
relay
TCS 15 2 60 1 60 0 0 0 0 0
MVAJ 150 2 600 1 0 0 0 600 0 0

MICOM c264 40 1 40 1 40 0 0 0 0 0
Annunciator 10 Busbar & common 1 1 10 1 10 0 0 0 0 0
P741 16 1 16 1 16 0 0 0 0 0

Meter 5 4 40 1 10 0 0 0 0 0
Indicator 1 10 20 1 20 0 0 0 0 0
Aux XFR 5 RTCC 5 2 50 1 50 0 0 0 0 0
AVR 5 1 10 1 10 0 0 0 0 0
Annunciator 10 1 20 1 20 0 0 0 0 0

132kV line
ISOLATOR(12)+132kV bus
Disconnector 5 isolator(2)+132KV trx 20 100 0.5 50 0 0 0 0 0
feeder(6)+132KV
transformer feeder(2)

GCB Drive
8 15 120 0.5 60 0 0 0 0 0
Box(132KV)
Total power For SIX feeders 1400 0 0 2700 0 600
 Table-2
POWER
POWER Continuous Tripping Emergency
EQUIPMENT LOCATION & NO. NO. CONSUMPTION( Co efficient Closing Peak Motor REMARKS
CONSUMPTION Load peak Lighting
Watt)
Tripping
330 24 7920 1 0 7920
coil
Single Pole 4nos(GCB)
closing
330 12 3960 1 0 3960
coil
Tripping
330 6 1980 1 0 1980
coil
132kV CB Gang operated 3nos(GCB)
closing
330 3 990 1 0 990
coil
Tripping
330 16 5280 1 0 5280
coil
11kV CB(outgoing) 2nos(GCB)
closing
330 16 5280 1 0 5280
coil
Tripping
330 4 1320 1 0 1320
coil
11kV CB(incoming) 2nos(GCB)
closing
330 2 660 1 0 660
coil
Power per Feeder 0 10890 16500 0 0
Simultaneity of feeders 1 0.04 1 0.04 1
Power for all 6 feeders 0 435.6 16500 0 0

Summation of table 1 & 2

Closing Tripping Emergency
Continuous Load
Peak peak Lighting
Table 1 1400 0 2700 600
Table 2 0 435.6 16500 0
Total Power 1400 435.6 19200 600
Total Current 12.73 3.96 174.55 5.45
 LOAD CYCLE TABLE & GRAPH
Period (min) Duration LOAD DESCRIPTION LOAD(A)
0--1 1 min Momentary tripping load+continuous load+emergency load (174.55+12.73+5.45)= 192.73 A
1--2 1 min Momentary closing load+continuous load+emergency load (3.96+12.73+5.45) = 22.14 A
2--60 58 min continuous load+emergency load (12.73+5.45) = 18.18 A
60--298 238 min continuous load (12.73) = 12.73 A
298--299 1 min Momentary tripping load+continuous load (174.55+12.73) = 187.28 A
299--300 1 min Momentary closing load+continuous load (3.96+12.73) = 16.69 A

LOAD
200
195
190
185
180
175
170
165
160
155
150
145
140
135
130
125
120
115
110
105
100
95 LOAD
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0
9
18
27
36
45
54
63
72
81
90
99
108
117
126
135
144
153
162
171
180
189
198
207
216
225
234
243
252
261
270
279
288
297
Nominal Temperature 30ᵒC Cell Cell Mfg: Cell Type:
Lowest 20ᵒC Voltage HBL Nickel Cadmium
Highest 45ᵒC 1.2V

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs
Section 1-First 1 Period(s) Only-if A2 is greater than A1. Go to section 2
1 A1 A1-A0 M1 t=M1
192.73 192.73 1.00 1.00 0.505 97.33
Total 97.33

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs

Section 2-First 2 Period(s) Only-if A3 is greater than A2. Go to section 3

1 A1 A1-A0 M1 t=M1+M2
192.73 192.73 1.00 2.00 0.55 106.00
2 A2 A2-A1 M2 t=M2
22.14 -170.59 1.00 1.00 0.505 -86.15
Total 19.85

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs

Section 3-First 3 Period(s) Only-if A4 is greater than A3. Go to section 4

1 A1 A1-A0 M1 t=M1+M2+M3
192.73 192.73 1.00 60.00 1.325 255.37
2 A2 A2-A1 M2 t=M2+M3
22.14 -170.59 1.00 59.00 1.31 -223.47
3 A3 A3-A2 M3 t=M3
18.18 -3.96 58.00 58.00 1.3 -5.15
Total 26.75
(1) (2) (3) (4) (5) (6) (8)
Period Load(Amperes) Change in Duration of Time to End of Capacity Rating Factor Required Section
Load Period section(Minutes) (kt) Size(3)×(6)
(Amperes) (Minutes) =Rated Amp Hrs

Section 4-First 4 Period(s) Only-if A5 is greater than A4. Go to section 5

1 A1 A1-A0 M1 t=M1+M2+M3+M4
192.73 192.73 1.00 298.00 4.98 959.80
2 A2 A2-A1 M2 t=M2+M3+M4
22.14 -170.59 1.00 297.00 4.97 -847.83
3 A3 A3-A2 M3 t=M3+M4
18.18 -3.96 58.00 296.00 4.96 -19.64
4 A4 A4-A3 M4 t=M4
12.73 -5.45 238.00 238.00 3.98 -21.691
Total 70.63

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Duration of Time to End of Capacity Rating Factor Required Section
Load Period section(Minutes) (kt) Size(3)×(6)
(Amperes) (Minutes) =Rated Amp Hrs
Section 5-First 5 Period(s) Only-if A6 is greater than A5. Go to section 6
1 A1 A1-A0 M1 t=M1+M2+M3+M4+M5
192.73 192.73 1.00 299.00 4.99 961.72
2 A2 A2-A1 M2 t=M2+M3+M4+M5
22.14 -170.59 1.00 298.00 4.98 -849.54
3 A3 A3-A2 M3 t=M3+M4+M5
18.18 -3.96 58.00 297.00 4.97 -19.68
4 A4 A4-A3 M4 t=M4+M5
12.73 -5.45 238.00 239.00 3.99 -21.7455
5 A5 A5-A4 M5 t=M5
187.28 174.55 1.00 1.00 0.505 88.14775
Total 158.91

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Duration of Time to End of Capacity Rating Factor Required Section
Load Period section(Minutes) (kt) Size(3)×(6)
(Amperes) (Minutes) =Rated Amp Hrs
Section 6-First 6 Period(s) Only-if A7 is greater than A6. Go to section 7
1 A1 A1-A0 M1 t=M1+M2+M3+M4+M5+M6
192.73 192.73 1.00 300.00 5 963.65
2 A2 A2-A1 M2 t=M2+M3+M4+M5+M6
22.14 -170.59 1.00 299.00 4.99 -851.24
3 A3 A3-A2 M3 t=M3+M4+M5+M6
18.18 -3.96 58.00 298.00 4.98 -19.72
4 A4 A4-A3 M4 t=M4+M5+M6
12.73 -5.45 238.00 240.00 4 -21.8
5 A5 A5-A4 M5 t=M5+M6
187.28 174.55 1.00 2.00 0.55 96.0025
6 A6 A6-A5 M6 t=M6
16.69 -170.59 1.00 1.00 0.505 -86.15
Total 80.74
Maximum section size = 158.91 AH

Required size = Maximum section size x Design margin x Temperature correction

factor x Aging factor

Battery size calculated = 201.0155 AH

Battery size selected = 461 AH

Standing DC loading for Protection, Control, Indications and alarms = (132kV line feeder control
and relay panel load + 132kv transformer feeder control and relay panel load + Bus coupler
feeder control and relay panel load )

= (536 + 292 + 146 ) Watts [ values were taken from Table 1]

= 974 Watts

= 8.854545455 Amp.

Battery size selected = 461 AH

Battery can backup the above mentioned load upto (330 / 14.436) = 52.06365503 Hours

Which Fulfills PGCB’s requirement.

Page-11
FLOAT CUM BOOST CHARGER SIZING CALCULATION
SELECTED BATTERY SIZE
DC Nominal Voltage
A) FLOAT CHARGER RATING
Float Charger Rating
Continuous Load Current
Float Charging Current
Float Charger Rating Calculated
Design Margin
Rating of Battery Charger
B) BOOST CHARGER RATING
Boost Charger Rating
Boost Charger Rating Calculated
Design Margin
Rating of Battery Charger
Battery Charger Rating Selected
RESULT
No. of Battery Cells
AH Capacity
Float cum Boost Charger rating
= 461 AH
= 110 V
= (Continuous load current + Float charging current)
= 12.73 A
= 2 mA per AH rating of battery
= 0.922 A
= 13.652 A
= 10%
= 14.72 A
= 20% of AH Rating of battery
= 92.2 A
= 10%
= 101.42 A
= 105 A
= 92 Nos.
= 461 AH.
= 105A at 110V DC
Page-12
 DVR Calculation
Number of Boost Voltage Total Boost Nominal Load % of Max Max load Required Voltage Voltage Drop at
No of Diode
Cell Per cell Voltage Voltage Voltage Voltage Drop At DVR Single Diode
110VDC
92 1.7 156.4 110 5 115.5 40.9 0.8 51.13
 ANNEXURE-2

Local Station- UPS

Sr.No Equipment Description Power Req No of Unit Actual

Consumption
1 HMI PC 300 3 900
2 Disturbance Recorder 100 1 100
3 Ethernet Switches 40 6 240
4 TFT Monitors 60 3 180
5 Laser Color Printer 190 2 380
6 GPS Time Sync Equipment 15 1 15
7 Gateway 15 2 30
TOTAL 1845 W

Power Factor = 0.8

KVA Requirement = 2.30625 kVA

Considering 85% Efficiency

And avg. diversity factor = 1273.05 W
Of 0.6 of UPS

Hence, Load on battery(W) = 1280 W