Battery Sizing Calculations

ELECTRICAL DESIGN
BATTERY SIZING CALCULATIONS DTP-E-GEN-1003-00

PROCEDURES
ROLTA INDIA LIMITED
EDS ELECTRICAL DESIGN

PROCEDURES
Battery Sizing Calculations
Calculations
DTP-E-GEN-1003-00
Revision History
Revision Revision Revision Department Head
Level Date Description (Approver)
This Document and all contained herein are proprietary of ROLTA INDIA LIMITED and is subjected to confidentiality restrictions
between ROTLA INDIA LIMITED and the Recipient. Copyright Reserved.
© Copyright 2008. Rolta India Issue Date: Page 1 of 28

Limited. All Rights Reserved.
Uncontrolled When Reproduced
ELECTRICAL DESIGN
PROCEDURES
Table of Contents
Sr. No Description Page no.

1 Purpose & Scope 3
2 Applicability 3
3 References 3
4 Procedure
4.1 General 5
4.2 Methodology of Calculation 6
4.3 User’s Manual 6
4.4 Sample Output 9
5 Battery Sizing & Battery Charger Sizing 10
6 Sample Calculation of Battery Sizing 25

ELECTRICAL DESIGN
PROCEDURES
1. Purpose & Scope
The purpose of this ETP is to describe the methods, which should be used to size, or to verify the
sizing of batteries and battery chargers and to determine the short circuit current available from the
battery and from the charger.
The purpose of this procedure is to provide:
 A pre-approved calculation template to aid in calculating sizes and available short circuit
currents for battery and charger.
 User instructions for EL-105 “Battery Sizing, Battery Charger Sizing, and available Short
Circuit Current,” for developing the user inputs and for performance of the calculation of
the size and short circuit current contribution for battery and battery.
2. Applicability
This procedure is applicable to all projects.
3. References
3.1 EL-105, “Battery & Battery Charger Sizing & Available Short Circuit Current,”
Version 00, Level 00.
3.2 Mathcad Version 7, Mathsoft Inc., Cambridge, MA
3.3 “IEEE Recommended Practice for Sizing Lead-Acid Batteries for Stationary
Applications,” IEEE Standard 485-1997.
3.4 “IEEE Recommended Practice for Design of the DC Auxiliary Power Systems for
Generating Stations,” IEEE Standard 946-1992.
4. Procedure
4.1 General
 The Electrical and Control Systems Engineer shall prepare a calculation to size batteries and
chargers and to determine available short circuit currents for all project procured DC
systems. DC components procured as part of a vendor supplied system (such as a fire alarm
system) where others are responsible for determining the electrical loads, do not require the
preparation of a calculation by the Engineer.

ELECTRICAL DESIGN
PROCEDURES
4.2 Methodology of Calculation
 This ETP contains a pre-approved calculation EL-105, including battery sizing

methodology adapted from IEEE 485, battery charger sizing methodology adapted
from IEEE 946, and methodologies for calculating available short circuit current
from the battery adapted from IEEE 946, Annex B, and available short circuit
current from the battery charger adapted from IEEE 946, Annex D.
4.3 User’s Manual

The EL-105 is divided into three sections:
a) Input
b) Calculation
c) Results
4.3.1 Input Data:

General:
 The input section of the EL-105 Mathcad template should be completely filled in. All
input data necessary for this calculation shall be obtained from the project design
criteria, specifications, or IEEE referenced standards.
IEEE Standards 485-1997 and 946-1992 describe all necessary calculation procedures
for the selection or development of input data.
The user is prompted to input the battery duty cycle data, the design margins, battery
manufacturer and battery cell data, and battery charger design parameters. All
definition equations denoted by “:=” shall be filled in.
The user can modify the information and text in the Input section.Text inputs shall be
contained in quotations (“TEXT”). The technical basis and source of the inputs shall
be properly documented in the body of the project calculation.
 Note: When entering data or text be careful that the cursor encompasses the data or
text only and not the entire equation. Otherwise, the equation will be deleted when
using “cut” or “backspace.” and cannot be undone. Should this occur, either start
a new or copy the deleted formula from the original file and paste it in the working file.
Load Duty Cycle
The load duty cycle shall be developed following the instructions in IEEE 485.
 Enter the loads for each step of the battery duty cycle in matrix “A” and associated
durations in matrix “M.”
 The input matrices should be adjusted for the number of periods needed for the duty
cycle by using “CTRL M” and adjusting the number of rows in each matrix

ELECTRICAL DESIGN
PROCEDURES
accordingly.
 MathCAD will not handle a single element matrix. If the load duty cycle is a
continuous value, such as for a UPS battery, use a 2 row by 1 column matrix and
assign the value of zero to the second row element
Enter random load, if required, and the associated time duration.
Design, Aging Margin, & Battery Room Temperature

Enter design margin, aging factor, and electrolyte temperature in degrees F.
 Design margin and temperature are project-determined values. IEEE 485
recommends a design margin of 10-15%. The temperature should be the lowest
expected temperature for the battery room.
Provide reference for design temperature.
Battery Type
Select a battery manufacturer and cell type and enter this text as shown on the
template.
 Enter the nominal cell voltage, typically 2.00 Volts-per-cell.
 Enter the minimum cell voltage and total number of cells. Consult IEEE 485 or the
specialist for direction in determining these values.
Enter the values for time durations (all combinations) and lookup the associated
Amperes-per-positive-plate (R factors) for each time. Enter these into matrix “R.”
The user can look ahead to page 9 of the calculation to determine the needed values
of time from the calculated time matrix “T,” and then enter the values in matrix
“R.”
Enter the total number of plates in the “TotalPlates” matrix based on the selected
manufacturer’s cell data sheet. Enter the associated 8-hour Ampere-hour discharge
ratings in the “BattSze_Ah,” matrix. If additional sizes or a change in the cell type
needs to be made, this can be adjusted at any time.
From the manufacturer’s initial voltage curve for the chosen battery cell type select
two points and enter the voltage and Amperes-per-positive-plate values for each
point.
Battery Charger Design Parameters

The battery charger input data should be entered as follows:
8 to 24 hours recharge time.
Recharge efficiency factor of 1.1.
Continuous load Amperes that must be served by the charger during normal plant

ELECTRICAL DESIGN
PROCEDURES
operations (ac restored) while the battery is being recharged.

Largest combination of noncontinuous loads that would be likely to be connected
to the bus simultaneously during normal plant operations.
The “StdCharger” matrix lists the most commonly available charger sizes. If
necessary, the user can add sizes to this matrix by using “CNTRL M.”
4.3.2. Calculation
Template parameters are set. These parameters are not user adjustable without
removing the lock on the pre-approved calculation. Special functions are defined to
allow the creation of a graphical presentation of the load duty cycle entered.
Calculation of Battery Size

The template calculates the size of the battery using the positive plate method of
calculation for sizing lead-acid batteries taken from IEEE 485.
Temperature correction factors from IEEE 485 have been included in the template
for automatic lookup by Mathcad.
The number of positive plates is calculated using design margins from the input
and a lookup feature determines the Ampere-hour size of the battery based on the
input data.
Calculation of Battery Charger Size
The template calculates the size of the charger based on the calculation
methodology of IEEE 946. This method compares the Ampere-hours from the
battery with the sum of the continuous and non-continuous loads and selects the
larger sized charger.
The template calculates two charger sizes based on the IEEE 946 method
comparing the “sum of the continuous and non-continuous loads” with each of the
following:
1. The load duty Ampere-hours discharged from the battery.
2. The 8 hour Ampere-hour rating of the selected battery.
Calculation of Battery and Charger Short Circuit Current

Battery short circuit current is calculated automatically using the input data from
the initial voltage curve of the battery.
Battery charger short circuit current is calculated automatically using the input
data, and in accordance with Annex D of IEEE 946, is based on 1.5 times the full
load rated output.
The values of short circuit current for both battery and charger are calculated at
the nominal system voltage (typically 120 Vdc for a 60 cell battery) for use in the

ELECTRICAL DESIGN
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DC system fault current analysis calculation.
4.3.3. Results
The Calculation and Results sections of the MathCAD template is “locked”
to prevent accidentally changing the equations from the qualified MathCAD
template. The password to unlock the calculation section is “SW245.” If the
calculation section is unlocked, the engineer shall review and check the entire
calculation including the pre-approved areas. The date when the qualified Mathcad
files were locked is Friday, September 4, 1998. In order to properly print the date
stamp for the locked area on page 6 of the program, a non-postscript print driver
must be used.
The Results section repeats the essential input data and then prints the results of
The template for each section of the calculation, “Battery Size,” Battery Charger
Size,” and “Short Circuit Current Available.” This is done for convenience of
viewing the input data with the results.
4.3.4. Program Limitations and General Instructions

The methodology is based on sizing batteries of the lead-acid stationary battery
type, which includes Lead-Calcium, Lead-Antimony, and Lead-Selenium. It is
recommended to use the Lead-Calcium type for stationary battery use. It is not
suitable for use in sizing Nickel-Cadmium type batteries. Refer to IEEE
Standard 1115-1992 for guidance for this type of battery cell.
The template calculates battery charger size in the following two ways:
1. The larger of the Ampere-hours discharged from the battery or the
combination of continuous and non-continuous loads.
2. The larger of the rated Ampere-hour size of the selected battery or the
3. The more conservative approach using the Ampere-hour rating of
the battery is recommended in IEEE 946. The user should select the
method that satisfies the project specification requirements.
The template calculates the available short circuit currents for
batteries and chargers at their terminals. This data is intended for use as
input to a dc system fault analysis calculation. The value of charger short
circuit current should be selected based on the associated sizing method.
The calculation assumes the intercell connector resistance is included in the
manufacturer’s initial voltage curve. If the intercell connector resistance is

ELECTRICAL DESIGN
PROCEDURES
not included in the input data, the resulting short circuit current at the terminals
of the battery will be a conservatively higher value. The resistance values
of inter-rack and battery terminal cables shall be included in the DC
system fault current analysis calculation and are not included in this
calculation.
The heading and footer of the template can be modified, except that the left
hand section of the footer, “EL 105 V00 L00” shall not be changed.
MathCAD Version 7.0 or later and Windows 95 operating system are
required to run EL-105.
The Page Setup feature for the Mathcad files is set to ensure proper
printing as follows:
a) Letter 8.5 x 11 inch
b) Portrait
c) Margins are set: Left and Right are 1.0 inch; Top is 1.5 inch; Bottom is
1.0 inch
4.4. Sample Output EL-105
The entire output of EL-105 should be included as an attachment to a project
calculation. In the Methodology section of the project calculation, the
following text shall be included to describe the methodology used in EL-
105.
Attachment A (Note: Attachment A should represent the actual battery and
charger sizes calculated and not the appendix A example attached to this
ETP) is the output of EL-105, “Battery Sizing, Battery Charger Sizing, and
Available short Circuit Current,” a MathCAD template.
Attachment A includes a run of sample battery sizing, charger sizing, and
short circuit calculations. The battery data used is taken from the sample
calculations in IEEE 485, Figures A1 and A4.

ELECTRICAL DESIGN
PROCEDURES
5. BATTERY SIZING, BATTERY CHARGER SIZING

AND AVAILABLE SHORT CIRCUIT CURRENT
References:
1. IEEE 485 - 1997, “IEEE Recommended Practice for Sizing Lead-Acid Batteries for
Stationary Applications.”
2. IEEE 946 -1992, “IEEE Recommended Practice for the Design of DC Auxiliary
Power Systems for Generating Stations.”
I. INPUT
A. Load Duty Cycle
The load duty cycle is developed per instructions contained in IEEE 485.
Loading of each section Time duration of each section

of battery discharge, in of battery discharge, in minutes
Amperes ( Column 2 in (Column 4 in IEEE 485,workshe
IEEE 485, worksheet Fi- -et Figure A-4).
gure A-4).
320 1
100 29
280 30
A= B=
200 60
40 59
120 1

ELECTRICAL DESIGN
PROCEDURES
Note: Use CTRL "M" to insert or delete rows and columns in the above matrices.
.Random A := 100 Random Current, A
Random M :=1 Time duration of random
current, minutes
B. Design, Aging Margin, & Battery Room Temperature
DesignMargin ----------------- 1.15

AgingFactor ----------------- 1.25
Electrolutye temp Low-------- 65 °F
C. Battery Type (USER TO MODIFY - TEXT IN QUOTES)
The battery manufacturer's type of cell is selected as follows:

Reference -------------------- "ABC-123"
Manufacturer----------------- "ABC"
Cell Type-------------------- "XYZ"
Cell Voltage------------------ 2.00 Volts-per-cell, nominal open circuit.
Minimum_Cell_Voltage--- 1.75 ----- Volts-per-cell
Total Number Cells = 60
R factor for battery:
1 st Column is the time duration associated with a specific R factor.
2 nd Column is R factor (Item 6A of Column 6 discharge period in IEEE 485, Sample Worksheet
Figure A-4).
Cell Type ="XYZ"
Available battery sizes, in terms of the total number of plates and Ampere-hour ratings for an 8 hour .
1 104 11
30 55.4 13
59 40 15
60 40 17
R= 90 32.5 TotalPlates= 19
119 27.5 21
120 27.5 23
150 24.0 25
179 21.5 27
180 21.5

ELECTRICAL DESIGN
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400
480
560
Batt Size_Ah= 640
720
800
880
960
64
1040
Note: Use CTRL "M" to insert or delet rows and columns in theabove matrices
Select two points on the manufacturer's initial voltage curve (V1,I1) and (V2, I2) that will be used for the
calculation of short circuit current: (Ref. IEEE 946-1992, Fig. B.1)
V1 1.90 Volts I1=60 Amperes per positive plate
V2 1.50 Volts I1=370 Amperes per positive plate
D. Battery Charger Design Parameters(Reference IEEE 946-1992, Sample A.3)

Tc8 Time to recharge the battery to approximately 95% of capacity (in hours)
(This is same as the symbol "T" in equation 1 of IEEE Std 946, which was
modified to avoid confusion with the use of "T" in battery sizing).
C=1.1 Constant that compensates for battery losses.
L c 50 Continuous dc load (Amperes), including future load growth (1.30

factor), in Amperes.
L n 60 The largest combination of noncontinuous loads in Amperes (as defined in

IEEE Std 485) that would likely be connected to the bus simultaneously
during normal plant operations.
3
6
12
25
50
75
100
StdCharger = 150 Standard Charger Sizes, Amperes DC

ELECTRICAL DESIGN
PROCEDURES
200
300
400
432
500
600
800
1000
II. Calculation
A. Template Parameters
see= rows A) sec 6 ORIGIN=1
i= 1 sec j= 1 sec
m= 1 sec n= 1 sec
Lookup num A1 A2) = for i €1 last A1) This defines a function called Vector "A,"
the
return S A2 if A1inum value in the is returned.If "A",then the messa
-ge "NF" (not found) is returned.
i
"NF"
Replicate A s) = k 0 Creates a function called

"Replicate" which doubles the
for i €1 last A) size of matrix A, repeating the
value of each element.
for j €1  s
TkjAi
k k 2

ELECTRICAL DESIGN
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+
T
LookupCol Vector sF) = for i €1 last Vector) Similar to "Lookup" function,
except only the first column
is used.
return S Vector if
"Out of Range"
B Duty Cycle Curve Plot

CREATING THE "CURRENT" VECTOR
AA = Replicate (A, 2) Double the size of the current "A" matrix and call
it "AA" matrix.
AA rows (AA)+1 : = 0
q :=1 ( rows AA)+1 ) Add an additional element to "AA" matrix at the
end and set it equal to zero so that current curve
will return to zero.
AAAq :=if ( q =1,0,AA q-1 Current Vector"AAAq"
CREATING THE "TIME" VECTOR

r:= 2 rows (M)
time1 := M1 Set first element of "time" matrix to first element of
"M"
timer : =Mr + time r-1 Add the next element of "M" matrix to the previous
element of "time" matrix.
Dbl_time := Replicate (time ,2 ) "Time" matrix is now doubled and called "Dbl_time."
q := 1 ( rows (Dbl_time)+1 ) Add additional element to "Dbl_time" matrix at the

beginning, and set it equal to 0.

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Dbl_timeplusq := if (q =1, 0 Dbl_time q-1)

q := 1 ( rows (Dbl_timeplus) + 1 ) Repeat above step to add one additional 0
element.
DDbl_timeplusq := if (q= 1, 0Dbl_timeplus q-1)
C. Change in Load
∆Ai :=if [i = 1, Ai,Ai - A (i-1) ]

Change in load Amperes of present
320 section load compared with the previous
-220 section load (Column 3 in IEEE 485 example.
180
∆A = -80

80
∆A_testi : = if (i= sec, Ai, Ai – Ai+1)

220 Change in load Amperes of previous section load compared with present
∆A_test section load.
 160
-80
120
D. Time to End of Section (minutes)

T(i i) := 0
T1, j := if [ j= 1, M1Mj + T1(j -1)

Ti,j :=if [ i= 1 ,Ti,jT(i – 1j) – M (i-1)] .
Tij := if ( Ti,j ≤ 0,0, Ti,j )
Ti,j := if ( ∆ - testj < 0,0,Ti,j ) Eliminates section calculation if load duration of

the next section is greater than present section,
i.e., Ai+1 is greater than Ai
1 0 60 120 0 180
ime to end of section, in minutes.
0 0 30 90 0 150 Columns represent each section;

ELECTRICAL DESIGN
PROCEDURES
T= 0 0 0 60 0 120 rows represent the period within

0 0 0 0 0 60 each section.
0 0 0 0 0 1
E. IEEE 485 Temperature Correction Factors
The first column is the electrolyte temperature in degrees F. The second column is the correction
factor from Table 1 of IEEE 485.
25 1.520 78 0.980
30 1.430 79 0.987
35 1.350 80 0.980
40 1.300 81 0.976
45 1.250 82 0.972
50 1.190 83 0.968
55 1.150 84 0.964
60 1.110 85 0.960
65 1.080 86 0.956
Table 1a = 66 1.072 Table 1b = 87 0.952
67 1.064 88 0.948

ELECTRICAL DESIGN
PROCEDURES
68 1.056 89 0.944
69 1.048 90 0.940
70 1.040 95 0.930
71 1.034 100 0.910
72 1.029 105 0.890
73 1.023 110 0.880
74 1.017 115 0.870
75 1.011 120 0.860
76 1.006 125 0.850
77 1.000
Table1 := stack (Table 1a,Table1b )

TempCorrFactor := Lookup ( ElectrolyteTempLow Table11 )
TempCorrFactor 1.11
F. Battery Size - Positive Plate Method (R Factor)
R1 : =R <1> R2 := R <2> Divides the 2 column matrix, "R," into two vectors.
Rmatrix i,j : = if ( Ti,j = 0, 0,Lookup (Ti,j ,R1,R2 ))
This is matrix of R factor of each value of

time in the matrix ‘T’. If the time in “T” is
zero, then the value in “RMatrix” is set to
zero. If a value in “T” is not found in matrix
“R”, an input, then “NF” (Not Found) is
reported. The user has to then to correct his
input matrix R by inserting missing value(s).

ELECTRICAL DESIGN
PROCEDURES
This replicates DA into a matrix of identical columns.
This calculates the required section size (Column 7 in IEEE 485) , the number of positive plates for each
period in each section.
This is the section size of each section.The subtotal of each column of matrix “Col 7” in
Ampere-hours.
MaximumSectionSize = max (SubtotalCol7) This is maximum section size, in positive plates.

MaximumSectionSize 7.1748 Positive plates, maximum section size
Random A This is the number of positive plates

Random Section Size: =
Lookup (Random M R1R2) required for the random load.

ELECTRICAL DESIGN
PROCEDURES
RandomSectionSize 0.962 Positive plates, random load.
UncorrSizeRFactor: = MaximumSectionSize + RandomSectionSize

UncorrSizeRFactor: = 8.136 Uncorrected total number of positive plates.
PositivePlatesRq: = UncorrSizeRFactor X TempCorrFactor X DesignMargin X AgingFactor 

PositivePlatesRq: = 12.63
PositivePlates: = ceil (PositivePlatesRq)
PositivePlates: = 13 Total number of positive plates required.
Plates: = (2 X PositivePlates) + 1
Plates = 27 Total number of plates required.
AmpHour_SizeR:= Lookup (Plates TotalPlates BattSze_Ah)
AmpHour_SizeR = 1040 Ampere-hour size of battery required (R factor)
G. Charger Size
Charger size based on Ampere-hours discharged from the battery:
Total ampere hours discharged from the battery during its specified duty cycle, Ampere-Hours.
I 1= L c + C Ah I1 = 144.971 Minimum required charger size,Ampere
Tc (Equation 1 from IEEE 946 ).
I 2 = Lc + L n I2 = 21.78 Sum of continuous and noncontinuous loads,

Amperes (Equation 2 from IEEE 946).
I 3= if (I 1, I 2I 1 I 2 ) I3 = 144.971 Larger of the two above sizes.
Charger_Size:= LookupCol (StdCharger I 3 1)
Charger_Size 150 Amperes DC, based on Ampere-Hours

discharged from the battery.
Charger size based on the rated size of the

selected battery:
Minimum required charger size, based on

Ampere-hours size of selected battery

ELECTRICAL DESIGN
PROCEDURES
(Equation 1 from IEEE 946).
Sum of continuous & noncontinuous loads, Amperes (Equation 2 from IEEE 946)
Larger of the two above sizes.
Selected_Charger_Size:= LookupCol( StdCharger , I 5 , 1)

Selected_Charger_Size 200 Amperes DC, based on rated Ampere-hours of the
selected battery.
H. DC SOURCE SHORT CIRCUIT CONTRIBUTION

Battery (Based on IEEE Standard 946, Annex B):
The internal resistance of a cell is calculated from the slope of the initial volts line of the
Published discharge characteristic curve of the manufacturer. The internal resistance is
Determined as follows:
PositivePlates = 13 Number of positive plates
Rp=( V1 - V2) Rp =1.29 x10-9 Ohms per positive plate.

(I2 -
I1)
Rp= Rp Rt =9.926 x10-5
Positive plates Total internal resistance of cell
Rb Rt Total_Number_Cells Rb 5.955 x10-3 Ohms,total battery resistance.
The short circuit current available at the cell terminals is found from Ohm's law as follows:
CellVoltage 2.00 Volts/cell, nominal cell voltage
Batt_Voltage = CellVoltage Total_Number_Cells
Batt_Voltage 120 Volts, nominal battery voltage
Ic1 20150 Amperes, available short circuit current
2. Battery Charger (Based on IEEE Standard 946, Annex D):
The maximum battery charger available continuous short circuit current is 1.5 times the full
load current rating of the charger.
Charger Voltage: = Batt_Voltage

Charger Voltage = 120 Volts, DC
ELECTRICAL DESIGN
PROCEDURES
Charger based on the larger of the the Ampere-hours discharged from the battery or the
combination of continuous and non-continuous loads:
Charger_Size 150 Amperes
Icharger_fault=1.5 charger_Size
Icharger_fault =225 Amperes

Charger based on the larger of the rated Ampere-hour size of the battery or the
combination of continuous and non-continuous loads:
Selected_Charger_Size = 200 Amperes

Icharger_Selected_fault:= 1.5 Selected_Charger_Size.
Icharger_Selected_fault = 300 Amperes
A. Battery Size:
1. Inputs: Load Duty Cycle

Section Amperes Time (minutes)
320
1
100
29
280
A= M= 30
200 60
59
40
1
120

ELECTRICAL DESIGN
PROCEDURES
For load duration curve see the following curve-----

ELECTRICAL DESIGN
PROCEDURES
DesignMargin =1.15
AgingFactor =1.25
ElectrolyteTempLow =65 Degrees F, lowest electrolyte temperature
TempCorrFactor =1.08
2. Results:
Minimum_Cell_Voltage =1.75 Volts per cell end voltage

ELECTRICAL DESIGN
PROCEDURES
Total_Number_Cells =
 60 Total number of cells
PositivePlates =13 Number of positive plates
Plates =27 Total number of plates required.
AmpHour_SizeR =1040 Ampere-hours for an 8 hour discharge to the

specified Volts-per-cell end voltage.
Manufacturer ="ABC" Cell_Type ="XYZ"
B. Battery Charger Size:
1. Inputs:
T c= 8 Hours, recharge time
C =1.1 Recharging efficiency constant
L c =50 Amperes, continuous DC load
L n= 60 Amperes, largest combination of noncontinuous loads
2. Results:
Charger_Size =150 Amperes DC, based on the larger of the the
Ampere-hours discharged from the battery or
the combination of continuous and non-continuous loads.
Selected_Charger_Size =200 Amperes DC, based on the larger of the rated

Ampere-hour size of the selected battery or the
C. Short Circuit Current Available
1. Inputs:
CellVoltage =2.00 Volts per cell, nominal
Initial Voltage Curve Data

V1 = 1.90 Volts I1 = 60 Amperes per positive Plate.
V2 = 1.50 Volts I2 = 370 Amperes per positive Plate.
2. Results :

ELECTRICAL DESIGN
PROCEDURES
a. Battery Short Circuit Current

Batt Voltage = 120 Volts, DC, nominal battery short circuit voltage.
Ic1 = 20150 Amperes, available battey short circuit current

b. Battery Charger Short Circuit Current
Charger Voltage = 120 Volts, DC, nominal charger short circuit voltage.
Charger based on the larger of the Ampere-hours discharged from the battery or the
Icharger Fault = 225 Amperes, available charger short circuit current
Charger based on the larger of the rated Ampere-hour size of the battery or the
combination of continuous & non-continuous loads:
Icharger Selected Fault = 300 Amperes, available charger short circuit current.
6.SAMPLE CALCULATION OF BATTERY SIZING
1.0 Site and system Conditions

Ambient temp. : Max: 46.6°C, Min: -0.7°C
Design ambient temp. : Max: 45°C, Min: 10°C (for battery sizing)
Maximum voltage : 220, +10% 242V (as per Bid package)

ELECTRICAL DESIGN
PROCEDURES
Minimum voltage : 220, -10% = 198 V (as per Bid. package)

End cell voltage : 1.16V (as per Bid package)
2.0. Battery sizing calculation

2.1 No of cells
Number of battery cells shall be based on the following
No.of cells : Maximum allowable system voltage/Float charging voltage per cell
=242V/ 1.41 = 171.63 = 172
Minimum system voltage ≥ No of cells x End cell voltage = 172 x 1.16= 199.52V
No of cells selected : 172
2.2 Calculation of load cycle

2.2.1 Calculation of continuous electrical loads (I2)
TOTAL
LOAD(W) TOTAL
S.NO DESCRIPTION QTY NO OF
UNIT ITEM LOAD(W)
PANEL
Indicating lamps for HV sw.bd (6.6kV &

1 3 per panel 34 2.5 255
33kV)
2 Indicating lamps for MV sw.bd 3 per breaker feeder 70 2.5 525
3 86 relay 2 per sw.bd 10 3.0 60
4 Aux.relay 1 per bkr feeder 100 3 300
50% of HV and MV
5 Motor protection relay 13 15 195
motors
As per project design

6 Motor diff. relay 3 15 45
data
7 Under voltage relay 4nos per sw.bd 5 15 300
8 ELR for motors rated above 22KW 50% of motors I2 3 36
9 Annunciation panel loads As per design data — — —
10 DC lighting load As per plan layout - - 2200
11 Misc.loads such as EPABX,LCP etc. As applicable - - -

ELECTRICAL DESIGN
PROCEDURES
12 Owner’s load for critical lighting - - - 1000
-
13 Owner’s DC load for Elect. Control - - 2000
.
14 ECS Load 2000
15 Any other load - - - -
Total load = 8916 watts

TotaI current (I2) 40.55 Amps
2.2.2 Calculation of electrical load (I4)
TOTAL NO OF LOAD(W) TOTAL

S.NO DESCRIPTION QTY
PANEL UNIT ITEM LOAD(W)
HV incomer bkr tripping on

1 2 no. per swbd 2 300 600
U/V
MV incomer bkr tripping on

2 2 no. per swbd 7 200 1400
U/V
6 nos. - 300W
Breaker fed motor tripping
3 50% HV and MV motors 13 (HV) & 7 nos. 3200
on U/V
– 200W(MV)
1 per HV panel + 4 per

4 Aux.relay 46 3 138
PCC / EPMCC
Closing of EPMCC
5 1No. 1 200 200
incomer

TotaI current (I4) = 25.173 Amps
2.2.3 Calculation of electrical load (I5)

ELECTRICAL DESIGN
PROCEDURES
TOTAL NO OF LOAD(W) TOTAL

DESCRIPTION QTY
PANEL UNIT ITEM LOAD(W)
S.NO
Closing of main HV
I 2 nos. per substation 2 300 600
incomer bkr
Closing of main MV
2 2 nos. per substation 2 200 400
incomer bkr
Breaker spring charging

3 2 nos. per substation 2 400 800
motor
1 per HV panel + 4 per PCC

4 Aux.relay 46 3 138
/ EPMCC

TotaI current (I5) = 8.809 Amps
2.24 Calculation of random electrical load (IR)
IR = load expected during any period of the duty cycle
= NIL Amps.
Electrical Loads for various duty cycle are

First minute duty cycle I1 =I2 + I4 = 40.53 + 25.173 = 65.703 for duration of’ M 1 minutes = Approx.
66A for 1 min.
Next duty cycle I2 = I2 = 40.53 A for duration of M2 minutes
= Approx. 41A for 118 min Last minute duty
cycle I3=I2+I5 = 40.53 + 8.809 = 49.339 for duration of’ M3 minutes
= Approx. 50A for 1 min Random load if any
IR = lR for duration of MR minutes - NIL
Loads and time duration is tabulated as shown below
2.3 Duty cycle diagram
S. NO LOADS(A) DURATION(MIN) REMARKS
1.0 I1 66 1

ELECTRICAL DESIGN
PROCEDURES


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ELECTRICAL DESIGN

BATTERY SIZING CALCULATIONS DTP-E-GEN-1003-00

ROLTA INDIA LIMITED

EDS ELECTRICAL DESIGN

© Copyright 2008. Rolta India Issue Date: Page 1 of 28

Sr. No Description Page no.

© Copyright 2008. Rolta India Issue Date: Page 2 of 28

1. Purpose & Scope

The purpose of this procedure is to provide:

This procedure is applicable to all projects.

3.2 Mathcad Version 7, Mathsoft Inc., Cambridge, MA

© Copyright 2008. Rolta India Issue Date: Page 3 of 28

4.2 Methodology of Calculation

 This ETP contains a pre-approved calculation EL-105, including battery sizing

4.3 User’s Manual

4.3.1 Input Data:

Load Duty Cycle

© Copyright 2008. Rolta India Issue Date: Page 4 of 28

Design, Aging Margin, & Battery Room Temperature

Battery Charger Design Parameters

© Copyright 2008. Rolta India Issue Date: Page 5 of 28

operations (ac restored) while the battery is being recharged.

Calculation of Battery Size

Calculation of Battery and Charger Short Circuit Current

© Copyright 2008. Rolta India Issue Date: Page 6 of 28

DC system fault current analysis calculation.

4.3.4. Program Limitations and General Instructions

© Copyright 2008. Rolta India Issue Date: Page 7 of 28

© Copyright 2008. Rolta India Issue Date: Page 8 of 28

5. BATTERY SIZING, BATTERY CHARGER SIZING

Loading of each section Time duration of each section

© Copyright 2008. Rolta India Issue Date: Page 9 of 28

B. Design, Aging Margin, & Battery Room Temperature

DesignMargin ----------------- 1.15

C. Battery Type (USER TO MODIFY - TEXT IN QUOTES)

The battery manufacturer's type of cell is selected as follows:

© Copyright 2008. Rolta India Issue Date: Page 10 of 28

Batt Size_Ah= 640

D. Battery Charger Design Parameters(Reference IEEE 946-1992, Sample A.3)

C=1.1 Constant that compensates for battery losses.

L c 50 Continuous dc load (Amperes), including future load growth (1.30

L n 60 The largest combination of noncontinuous loads in Amperes (as defined in

© Copyright 2008. Rolta India Issue Date: Page 11 of 28

see= rows A) sec 6 ORIGIN=1

Replicate A s) = k 0 Creates a function called

© Copyright 2008. Rolta India Issue Date: Page 12 of 28

B Duty Cycle Curve Plot

AAAq :=if ( q =1,0,AA q-1 Current Vector"AAAq"

CREATING THE "TIME" VECTOR

q := 1 ( rows (Dbl_time)+1 ) Add additional element to "Dbl_time" matrix at the

© Copyright 2008. Rolta India Issue Date: Page 13 of 28

Dbl_timeplusq := if (q =1, 0 Dbl_time q-1)

DDbl_timeplusq := if (q= 1, 0Dbl_timeplus q-1)

∆Ai :=if [i = 1, Ai,Ai - A (i-1) ]

∆A_testi : = if (i= sec, Ai, Ai – Ai+1)

D. Time to End of Section (minutes)

T1, j := if [ j= 1, M1Mj + T1(j -1)

Tij := if ( Ti,j ≤ 0,0, Ti,j )

Ti,j := if ( ∆ - testj < 0,0,Ti,j ) Eliminates section calculation if load duration of

© Copyright 2008. Rolta India Issue Date: Page 14 of 28

T= 0 0 0 60 0 120 rows represent the period within

E. IEEE 485 Temperature Correction Factors

Table 1a = 66 1.072 Table 1b = 87 0.952

© Copyright 2008. Rolta India Issue Date: Page 15 of 28