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Battery Charger Sizing SS 1 Rev 03 PDF
Battery Charger Sizing SS 1 Rev 03 PDF
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001,
REFERENCE Rev.-F )
DOCUMENT NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV
of V Page-55 of 272 Section 2.3
TABLE OF CONTENT
2 REFERENCE CATALOGUE 2
3 DC LOAD CALCULATION 3
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
REFERENCE DOCUMENT
2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-
NO.
55 of 272 Section 2.3
WORKSHEET‐1
BASIS & ASSUMPTIONS
1.0 PURPOSE
The purpose of this calculation is
a) To establish battery load cycle for 110V DC Battery.
b) To determine the number of cells for 110V DC Battery.
c) To determine the Ampere ‐ Hour rating of 110V DC Battery.
d) To determine the rating of Battery Charger.
2.0 DESIGN BASIS & ASSUMPTIONS
2 1 The sizing of Battery has been done on the basis of IEEE
2.1 The sizing of Battery has been done on the basis of IEEE ‐ 485 :1997
485 :1997
2.2 The sizing of Battery Charger has been done on the basis of IEEE ‐ 946 : 1995.
2.3 110V DC Battery Bank shall be comprised of a bank of 2.0V rated Lead acid plante type battery.
(Reference: Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume ‐ IV of V Page‐55 of 272 Section
2.4 110 V Lead acid plante type Battery Bank and Float cum Boost Charger has been considered for catering Control, Protection &
Indication Load of 6.6 KV Switchboard of SS1, ACBs of PMCC Panel & other miscllenous loads.
2.5 The End Cell Voltage of each Battery Cell is 1.85 Volts.
(End Cell Voltage ( ECV ) is taken as 1.85V as per Design Criteria of Technical Specification Volume IV of V, Clause ‐ 2.3.2, Pg 56
of 272)
2.6 Battery is sized for a back up duration of 10 hour for Load Duty Cycle.
(Reference: Since nothing has been specified in Technical Specification, we have assumed 1hour back up duration for Load duty
Cycle ).
2.7 DC Output Voltage shall be adjustable between +10% & ‐10% of Nominal rated voltage.
(Reference: Technical Specification of DC System, Volume ‐ IV of V, Clause ‐ 2.3.3.2.5,ii , Page ‐ 61 of 272).
2.8 An Ageing Factor of 1.25 has been considered.
2.9 A nominal Design Margin of 10% has been considered for standard over sizing of battery to allow for unforseen operating
conditions of the battery due to improper maintenance, recent discharge or ambient temperature lower than the anticipated
or both.
(Reference: as per IEEE ‐ 485 :1997, Clause‐6.2.2)
2.10 Battery is designed to be operated at a temprature range of 19 deg C to 33 deg C.However, design operating temprature has
been considered as 27 deg C.
(Reference: Technical Specification of DC System, Volume ‐ IV of V, Clause ‐ 2.3.3.1.2, Page ‐ 59 of 272).
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
REFERENCE DOCUMENT
2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-
NO.
55 of 272 Section 2.3
WORKSHEET‐1
2.11 Temperature Correction Factor has been taken as 1.25 at 8 deg C as per IEEE 485 :1997
2.12 Value of Capacity factor (KT) at 1min & 600min has been obtained from Manufacturer's Catalogue as attached herewith in
"Reference Catalogue" worksheet. Further, the value of Capacity Factor (KT) at 588min & 599min are derived from the above
two terminal values by the method of extrapolation.
2.12 Float Charge Voltage is 2.25 Volts per Cell .( As per Manufacturer's Catalogue ) we have consider one of the mfg. details for
calculatuion ,after finalisation we will revsied it submit again
2.13 Boost Charge Voltage 2.60 Volts per Cell. ( As per Manufacturer's Catalogue ) we have consider one of the mfg. details for
calculatuion ,after finalisation we will revsied it submit again.
2.14 While sizing of Battery Charger, it has been considered that battery shall have maximum recharge time of 10 hours as
described herewith in "Reference Catalogue" worksheet.
2.15 This DC System will feed power to following loads:
a) Control, Protection and Indication circuit of 6.6 KV HT Panel,
b) Tripping Coil of incomer & buscoupler ACBs of PMCC Panel
2.16 The various loads for the battery duty cycle is consider as under
The following duty cycle is considered
a) The battery feeds the continuous loads of Indicating lamps,Relays,Contact multiplication equipment,etc. b) All
the breakers are tripped
c) At the end of the duty cycle,to resume power to the battery charger ,MV breakers are considered to be closed
2.17 Load Cycle Scenario
a) Following DC loads are considered For First 0 to 1minute of Load Duty Cycle as per standard engineering and system
requirement.
1) Tripping Coil of 6.6 KV HT Board Incomer VCB ‐ 1No.
2) Tripping Coil of 6.6 KV HT Board Transformer Outgoing VCB‐ 5No.(Including spare)
3) Tripping coil of 6.6KV HT Board Capacitor Outgoing VCB‐ 1No.
4) Tripping Coil of PMCC incomer ACB & Buscoupler ACB
5) Master Trip Relay for all incoming & outgoing feeder.
b) DC loads on a/c of control, indication, annunciation and protection devices have been considered for Entire 0 to 600 minute
duty cycle as per standard engineering and system requirement. 1)
All protection relay,Aux. Relay ,Indicating Lamps,Annunciator ,hooter Aux. Contactor
c) Following DC loads are considered at Last 599 to 600 minute duty cycle:
1) Closing Coil of 6.6 KV HT Board Incomer ‐ 1No.
2) Closing Coil of 6.6 KV HT Board Transformer Outgoing VCB‐ 5No.(Including spare)
3) Closing Coil of 6.6 KV HTBoard Capacitor Outgoing ‐ 1No.
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
REFERENCE DOCUMENT 1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of
272 S ti 23
Worksheet ‐2
REFERENCE CATALOGUE
1.0 END CELL VOLTAGE (ECV)
End Cell Voltage ( ECV ) is taken as 1.85V as per Design Criteria of Technical Specification Volume IV of V, Clause ‐ 2.3.2, Pg 56 of 272
2.0 TEMPRATURE CORRECTION FACTOR OF BATTERY AS PER IEEE ‐ 485
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
REFERENCE DOCUMENT 1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of
272 S ti 23
Worksheet ‐2
3.0 CAPACITY FACTOR (KT)
From above Capacity Factor Chart of chabbi, Capacity Factors at 27 deg C are derived as below:
Time ECV‐1 ECV‐2 ECV‐3
(Minute) (1.75V) (1.85V) (1.80V)
01 0.75 1.18 0.94
598 9 80
9.80
599 9.90
600 10
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
REFERENCE DOCUMENT 1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of
272 S ti 23
Worksheet ‐2
4.0 FLOAT CHARGE VOLTAGE (FCV) & BOOST CHARGE VOLTAGE (BCV)
As per Manufacturer's Catalogue
6.0 BATTERY RECHARGE TIME
Float charge Voltage at 27 deg C 2.25 Volts / Cell
Boost charge Voltage at 27 deg C 2.60 Volts / Cell
6.0 BATTERY RECHARGE TIME
As per Manufacturer's Catalogue, Battery Recharge time has been considered as 10 hours.
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
REFERENCE DOCUMENT NO.
2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of 272 Section 2.3
Worksheet ‐3
DC LOAD CALCULATION (in WATT) SUBSTATION
Feeder Load Description Quantity Continous Load Total Continous Load Tripping Load Closing Load
0 ~ 600min 0~600Min 0 ~ 1min (First Minute) 599 ~ 600min (Last Minute)
6.6 KV HT PANEL
Tripping Coil 1 0 0 200 0
Closing Coil 1 0 0 0 200
Spring charging for motor 1 0 0 0 200
Aux. Contactor 1 10 10 0 0
Breaker Contact multiplication Relay‐52X 1 3 3 0 0
Antipumping relay‐94(PLA) 1 6 6 0 0
Master Trip Relay‐86 (VAJHM23) 1 5 0 5 0
Trip Ckt Supervision Relay‐95(VAX31) 1 3 3 0 0
6.6 KV Incomer
(VCB)
AC & DC Fail Relay‐80 2 4 8 0 0
Micom P‐127 Relay 1 4 4 0 0
Auxiliary Relay(VAA11) 3 9 27 0 0
Digital Multi Function Meter 1 4 4 0 0
Annunciator (8 Window) 1 12 12 0 0
Hooter 1 15 15 0 0
Aux Contactor 1 10 10 0 0
Indication Lamps 14 2 28 0 0
Timer R1/R2 2 3 6 0 0
6.6 KV HT PANEL
Tripping Coil 5 0 0 1000 0
Closing Coil 5 0 0 0 1000
Spring charging for motor 5 0 0 0 200
Antipumping relay‐94(PLA) 5 6 30 0 0
Sensitive Earth Fault Relay‐50G(CTUM15) 5 2 10 0 0
Buchorz Relay‐Alarm Relay 5 3 17 0 0
6.6 KV Outgoing Master Trip Relay‐86(VAJHM23) 5 5 0 5 0
(VCB) for
Trip Ckt Supervision Relay‐95(VAX31) 5 3 15 0 0
Transformer ( X 5
Nos.)
Micom P‐127 Relay 5 4 20 0 0
Auxiliary Relay(VAA33) 15 9 135 0 0
Digital Multi Function Meter 5 4 20 0 0
Annunciator (8 Window) 5 12 60 0 0
Hooter 5 15 75 0 0
Aux Contactor 1 10 10 0 0
Indication Lamps 70 2 140 0 0
Timer R1/R2 10 3 30 0 0
6.6 KV HT PANEL
Tripping Coil 1 0 0 200 0
Antipumping relay‐94(PLA) 1 6 6 0 0
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
REFERENCE DOCUMENT NO.
2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of 272 Section 2.3
Worksheet ‐3
DC LOAD CALCULATION (in WATT) SUBSTATION
Feeder Load Description Quantity Continous Load Total Continous Load Tripping Load Closing Load
0 ~ 600min 0~600Min 0 ~ 1min (First Minute) 599 ~ 600min (Last Minute)
Master Trip Relay‐86(VAJHM23) 1 5 0 5 0
Trip Ckt Supervision Relay‐95(VAX31) 1 3 3 0 0
Micom P‐127 Relay 1 4 4 0 0
Digital Multi Function Meter 1 4 4 0 0
Annunciator (8 Window) 1 12 12 0 0
Auxiliary Relay(VAA33) 1 9 9 0 0
Hooter 1 15 15 0 0
Aux Contactor 1 10 10 0 0
Indication Lamps 9 2 18 0 0
Timer R1/R2 2 3 6 0 0
Battery Charger Panel
Indication Lamps 8 2 16 0 0
Annunciator (12 Window) 1 18 18 0 0
Hooter 1 0 0 0 0
PMCC Panel
Tripping Coil 1 0 0 200 0
Incomer from
27‐ Under Voltage Relay 1 4 4 0 0
Transformer
Micro Logic Release 1 2 2 0 0
Closing Coil 1 0 0 0 0
Micro Logic Release 1 2 2 0 0
a) Continous Load in (W) For 0~600 Minute 827.48
b) First Minute Load in (W) Between (0~1 Min) 1813.50
c) Last Minute Load in (W) Between (599~600 Min) 2000.00
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
REFERENCE 1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
DOCUMENT NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of 272 Section 2.3
Worksheet ‐4
BATTERY LOAD CYCLE DIAGRAM
TOTAL LOAD SUMMARY OF 110V DC SYSTEM ( SS‐1 OR SS‐2 SUBSTATION )
LOAD PROFILE (WATT/ AMP)
DESCRIPTION
Sr. No. CONTINUOUS LOAD TRIPPING* CLOSING/CHARGING* REMARKS
NOTES:
* : Momentary loads
LOAD CYCLE CALCULATION:
BATTERY DUTY CYCLE TABLE:
TIME (MINUTES) CURRENT (AMPS)
0 0.00
0 24.01
1 24.01
1 7.52
599 7.52
599 25.70
600 25.70
600 25.70
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
REFERENCE 1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
DOCUMENT NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of 272 Section 2.3
BATTERY DUTY CYCLE:
30.00
25.70
25.00
24.01
20.00
CURRENT- AMP
15.00
10.00
7.52 7.52
5.00
0.00
0 50 100 150 200 250 300 350 400 450 500 550 600 650
TIME-MINUTE
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
REFERENCE DOCUMENT NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-
55 of 272 Section 2.3
Worksheet ‐ 5
BATTERY AMPERE ‐ HOUR SIZING CALCULATION
BATTERY DUTY CYCLE
BATTERY BACK‐UP TIME : 600 MINUTES (ASSUMED BY SEI)
A1 : 24.01 AMPS FOR FIRST 1 MINUTE FOLLOWED BY
CAPACITY FACTOR (KT) AS PER MANUFACTURER'S CATALOUGE
DURATION (MINUTE) CAPACITY FACTOR
1 1.18
598 9.80
599 9.90
600 10.00
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
REFERENCE DOCUMENT NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-
55 of 272 Section 2.3
CALCULATION OF BATTERY AMPERE‐HOUR AS PER IEEE‐485
REQUIRED SECTION SIZE‐ (3) x
DURATION OF (6) RATE AH HRS
TIME TO END SECTION CAPACITY RATING FACTOR AT t
PERIOD LOADS (AMPS) CHANGE IN LOADS (AMPS) OPERATION
(MINUTES) MIN. RATE (Kt)
(MINUTES)
POS. VALUE NEG. VALUE
SECTION‐1 FOR FIRST PERIOD ONLY AND IF A2 >A1 THEN GO TO SECTION‐2
SECTION‐1 TOTAL AH 28.33
SECTION‐2 FOR FIRST TWO PERIODS ONLY AND IF A3>A2 THEN GO TO SECTION‐3
SECTION‐2 TOTAL AH 76.12
SECTION‐3 FOR FIRST THREE PERIODS ONLY AND IF A4>A3 THEN GO TO SECTION‐4
SECTION‐3 TOTAL AH 98.33
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing No.EL00001, Rev.-F )
REFERENCE DOCUMENT
2.Technical Specification of Battery ,Battery Charger & DC Distribution Board Volume - IV of V Page-55 of
NO.
272 Section 2.3
Worksheet ‐ 6
CALCULATION FOR QUANTITY OF CELLS
Maximum No. of Cells = Maximum System Voltage / Float Charging Voltage
= 121.00 / 2.25
= 53.78 Cells
Minimum No. of Cells = Minimum System Voltage / End Cell Voltage
= 93.50 / 1.85
= 50.54 cells
No. of Cells selected = 55
Selected No. of Cells in Battery Bank 55 Nos.
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing
REFERENCE DOCUMENT No.EL00001, Rev.-F )
NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board
Volume - IV of V Page-55 of 272 Section 2.3
Worksheet ‐7
BATTERY CHARGER SIZING
INCOMING :
Voltage : 415 ± 10% VAC
Freqyency : 50 ± 5% Hz
OUTGOUING :
Voltage : 110 VDC
LOAD CYCLE :
Continious Load (A2) : 7.52 Amps for 599 Min
First Minute Load (A1) : 24.01 Amps for 1 Min
Last Minute Laod (A3) : 25.70 Amps for 1 Min
BATTERY CAPACITY :
Cell selected : 200 AH
Charging Duration : 10 Hour
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DOCUMENT TITLE DC BATTERY & BATTERY CHARGER SIZING CALCULATION FOR SS-1 & SS-2
1.Overall Electrical Single Line Diagram For SS-1(DHC Tail End) (Drawing
REFERENCE DOCUMENT No.EL00001, Rev.-F )
NO. 2.Technical Specification of Battery ,Battery Charger & DC Distribution Board
Volume - IV of V Page-55 of 272 Section 2.3
CHARGER TYPE
Float cum Trickle cum Boost Charger
Design Margin‐20% : 1.20 (AS PER IEEE‐485‐1997)
CHARGER RATING:
A = (DM x L1) + (BIF x AH)
(RT)
Where,
A = Charger output current in ampere
DM = Design Margin‐20% = 1.20 (AS PER IEEE‐485‐1997)
L1 = Continuous DC Load Current = 24
BIF = Battery Inefficiency factor due to losses = 1.1 (AS PER IEEE ‐ 946:1992)
AH = Battery Ampere Hour Capacity = 200
RT = Battery Recharge Time
B tt R h Ti = 10
L1 = [ DC load of Control, Indication and Annunciation Circuit in normal operation] + [ Momentary Closing & Tripping
Load] + [ Float Charging Current of Battery]
L1 = 24.41 Amps
Therefore, A = Charger output current in ampere = 51.00 Amps
HENCE, SELCTED RATING FOR THE BATTERY CHARGER : 50 AMPS
BATTERY CHARGER SIZING CALCULATION FOR FLOAT CHARGER
CONTINUOUS DC LOAD CURRENT (ICC)= = 8
DESIGN MARGIN (25% )= = 1.25
FLOAT CHARGING CURRENT(Itc)= = 8.80
A (@ 160 mA per cellX 55 Nos. cells, as per Manufcaturer catalogue)
THE TOTAL REQUIRED CAPACITY OF THE FLOAT CHARGER IS CALCULATED AS: = ICC x 1.25 + ITC
= 8 X 1.25 + 8.80
REQUIRED CAPACITY OF FLOAT CHARGER = = 18.20 A
BATTERY CHARGER SIZING CALCULATION FOR BOOST CHARGER
DC NOMINAL VOLTAGE = 110 V
BOOST CHARGING RATING = 20% OF Ah OF BATTERY
= 0.2 X 200
= 40.0 A
DESIGN MARGIN = 20%
BATTERY CHARGER RATING = 48 A
BATTERY CHARGER RATING IS SELECTED FROM HIGHER OF FLOAT & BOOST CHARGING CURRENT, HENCE,
CALCULATED CAPACITY OF BOOST CHRGER 48 Amps
SELECTED CAPACITY OF BOOST CHRGER = = 50 AMPS
2 NOS ,100% RATED FLOAT CUM BOOST CHARGER AS PER SPECIFICATION
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