Document No: AR2-DOC-

Arayat-Mexico Phase 2 Solar Farm Project, Philippines 006-0002-00

Revision: A

DETAILED ENGINEERING DESIGN

June 10, 2022

ARAYAT-MEXICO PHASE 2
SOLAR FARM PROJECT
PHILIPPINES

DC & UPS System Battery Bank and

Charger Sizing
125VDC-1 Battery Bank (P2)

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Battery Bank 125VDC-1 (Phase-2):

Using Lead Acid Battery from SEC battery and PMI battery Charger manufacturers:
With reference to IEEE Std 1184-2006

Guide for Batteries for Uninterruptible Power Supply Systems (Criteria):

7. Battery Sizing

7.4 battery Sizing Calculations

7.4.1 UPS Efficiency and Power Factor

7.4.2 Adjusted battery Load Calculation

The nominal battery load should be adjusted for aging and operating temperature conditions.

Adjusted battery load = nominal battery load x aging margin x temperature correction factor

7.4.3 Voltage Window and Number of Cells

7.4.4 Cell Selection

7.5.3 Lead Acid Calculations

7.5.3.1 Initial Assumptions and Limiting Factors

7.5.3.2 Selection of Number of Cells and End Voltage

1.) Calculate system demand with reference to battery charger efficiency and battery load
adjustment:

125VDC-1 Battery Bank has a demand load of 1,942.75 Watts.

1,942.75 Watts ÷ 0.90 = 2,158.61 Watts – Charger efficiency as per PMI Charger manufacturer >80%
at full load, say 90% efficiency.

As a recommendation we shall consider the factors suggested: Aging Factor: 125%

Temperature Correction Factor (k): 1.056, assuming temperature drops from 25°C to 20°C
(See Table-1: Temperature correction factor)

Adjusted Battery Load = 2,158.61 Watts x 1.25 x 1.056

Adjusted Battery Capacity = 2,849.37 Watts

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2.) Calculate number of cells and end voltage:

With reference to SEC Microlyte Battery Model:

It has a nominal capacity of Nominal capacity (Ah) C/10 1.75VPC and float voltage of 2.25VPC ± 1% at
25ºC.

Assuming 135 VDC maximum rectifier equalizing voltage (as per charger setting) and max charge 2.25VPC

135VDC ÷ 2.25VPC = 60 Cells

At 110VDC minimum voltage cut-off

Minimum Charger Voltage ÷ Number of Cells

110VDC ÷ 60 Cells = 1.83VPC

As per SEC Battery Microlyte Model Unit, it has a rating of 1.75, 1.67 & 1.80 End of discharge voltage
(EOV).

3.) Calculate cell performance as per adjusted battery load:

2,849.37 Watts ÷ 60 Cells = 47.49 Watts / cell

With reference to SEC Microlyte Battery Model 12-MRT-275, it has a Power performance of 124 Watts per
cell for 3 hour battery back-up time.

4.) Calculate battery current discharge as per adjusted battery load:

2,849.37 Watts ÷ 108VDC = 26.48 Amperes, at 1.75V battery end voltage per cell (recommended).

Referring to SEC Microlyte Battery Model 12-MRT-275, it has a 64.80 Amperes at 3-hour discharge time
which is the nearest current capacity.

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With reference to IEEE Std 1115-2000:

DB-125VDC1 Connected Loads:

Circuit Load Description Connected Load Remarks

Number Load Current
(Watts) (A)
1-3 NDME Panel 250 2.0 Continuous Load
2-4 DS01/ES01 Aux. Control 200 1.6 Continuous Load
5-7 Spare Breaker 0 0 No connected Load
6-8 DS02/ES02 Aux. Control 200 1.6 Non-Continuous Load
9-11 Spare Breaker 0 0 No connected Load
10-12 DS03/ES03 Aux. Control 200 1.6 Non-Continuous Load
13-15 PCB Opening/Closing Coil-1 (Aux. Ckt.) 500 4.0 Non-Continuous Load
14-16 Spare Breaker 0 0 No connected Load
17-19 Line Protection Panel (M1) 100 0.8 Continuous Load
18-20 XF Protection Panel (M1) 80 0.64 Continuous Load
21-23 Spare Breaker 150 1.2 No connected Load
22-24 69kV Line Metering & Control Panel 80 0.64 Continuous Load
25-27 Spare Breaker 0 0 Continuous Load
26-28 RTU Panel 600 4.8 Continuous Load
29-31 Spare Breaker 0 0 No connected Load
30-32 Spare 0 0 Non-Continuous Load
33-35 Spare 0 0 No connected Load
34-36 Spare 0 0 No connected Load
38-40 Spare 0 0 No connected Load
Total Connected Load 2,360 18.88
Demand Factor 82.32% 82.32%
Demand Load 1,942.75 15.54

Battery Bank 125VDC1 connected loads duty cycle:

Period Connected Loads Total Amperes Duration (mins) Capacity (Ah)

1 Protection/Control Panels & Spare 10.08 180 30.24
2 PCB/DS/ES Aux Ckt. 8.80 20s (0.333 mins) 0.05328
3 No Load 0 0 0
18.88 Total 30.773

Notes:
DS & ES Opening & Closing Operation takes about 10-20 seconds
PCB/DS/ES do not operate simultaneously (i.e. only 1 equipment operate at a time)
PCB Motor Spring Charging takes about 5-10 seconds
PCB opening & closing do not operate simultaneously (i.e. only 1 operation at a time)
See DB-125VDC1 Panelboard Schedule for reference

Total Ampere-hour of SEC Microlyte 12-MRT-275: 64.80 Amps for 3-hours or 194Ah, see SEC Microlyte
Catalogue

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In relation to Ampere-hour (Ah) load duty cycle of 125VDC-1 Battery Bank at 30.773 Ah,
Battery model 12-MRT-275 with 64.80 Amps/194Ah battery capacity for 3 hours is sufficient since PCB and
DS auxiliary controls operate intermittently.

Therefore, 194 Ah > 30.773 Ah – OK

Float Voltage: 2.25VPC x (6 cells / battery) x 10 batteries = 135 Volts, see SEC Microlyte Battery catalogue

Therefore, use 10 units SEC 12-MRT-275 Battery Model for 125VDC-1 (Typical to 125VDC-2)

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125VDC-2 Battery Bank (P2)

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Battery Bank 125VDC-2 (Phase-2):

With reference to the previous computation for Battery Bank 125VDC-1:

1.) Calculate system demand with reference to battery charger efficiency and battery load
adjustment:

125VDC-2 Battery Bank has a demand load of 2,720 Watts.

2,720 Watts ÷ 0.90 = 3,022.22 Watts – Charger efficiency as per PMI Charger manufacturer >80% at
full load, say 90% efficiency.

As a recommendation we shall consider the factors suggested: Aging Factor: 125%

Temperature Correction Factor (k): 1.056, assuming temperature drops from 25°C to 20°C
(See Table-1: Temperature correction factor)

Adjusted Battery Load = 3,022.22 Watts x 1.25 x 1.056

Adjusted Battery Capacity = 3,989.33 Watts

2.) Calculate number of cells and end voltage:

With reference to SEC Microlyte Battery Model:

It has a nominal capacity of Nominal capacity (Ah) C/10 1.75VPC and float voltage of 2.25VPC ± 1% at
25ºC.

Assuming 135 VDC maximum rectifier equalizing voltage (as per charger setting) and max charge 2.25VPC

135VDC ÷ 2.25VPC = 60 Cells

At 110VDC minimum voltage cut-off

Minimum Charger Voltage ÷ Number of Cells

110VDC ÷ 60 Cells = 1.833VPC

As per SEC Battery Microlyte Model Unit, it has a 1.67, 1.75 & 1.80 End of discharge voltage (EOV).

3.) Calculate cell performance as per adjusted battery load:

3,989.33Watts ÷ 60 Cells = 66.49 Watts / cell

Refering to SEC Microlyte Battery Model 12-MRT-275, it has a Power performance of 124 Watts per cell for
3 hour battery back-up time.

4.) Calculate battery current discharge as per adjusted battery load:

3,989.33 Watts ÷ 108VDC = 36.94 Amperes, at 1.75 battery end voltage per cell (recommended).

Referring to SEC Microlyte Battery Model 12-MRT-275, it has a 64.80 Amperes at 3-hour discharge time

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With reference to IEEE Std 1115-2000:

Battery Bank 125VDC2 connected loads duty cycle:

Period Connected Loads Total Amperes Duration (mins) Capacity (Ah)

1 Prot./Ctrl/Comm. Panels & Spare 7.68 180 23.04
2 PCB Trip Coil-2 4.0 10s (0.333 mins) 0.0222
3 Spare (MVSG–Aux/ Motor Ch.) 18.40 10s (0.333 mins) 0.10212
30.08 Total 23.164

Note:
MVSG Motor Spring Charging takes about 5-10 seconds
Protection, Control & SAS Panels are continuous loads
See DB-125VDC2 Panelboard Schedule for reference

Total Ampere-hour of SEC Microlyte 12-MRT-275: 64.80 Amps for 3-hours or 194 Ah

In relation to Ampere-hour (Ah) load duty cycle of 125VDC-2 Battery Bank at 62.041 Ah,
Battery model 12-MRT-275 with 64.80 Amps battery capacity for 3 hours is sufficient since MVSG motors
and PCB Trip Coils operate intermittently.
Therefore, 194 Ah > 62.041 Ah – OK

Float Voltage: 2.25VPC x (6 cells / battery) x 10 batteries = 135 Volts, see SEC Microlyte Battery catalogue

Therefore, use 10 units SEC 12-MRT-275 Battery Model for 125VDC-2 (Typical to 125VDC-1)

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48VDC-1 & 2 Battery Bank (P2)

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Battery Bank 48VDC-1 (Phase-2):

With reference to the previous computation for Battery Bank 125VDC-1 & 2 and
IEEE Std 1115A – 2007, Recommended Practice for Sizing Nickel Cadmium Batteries
IEEE 1184, Guide for Batteries for UPS Systems.
7.5.4 Ni-Cd Calculations

7.5.4.1 Initial Assumptions and limiting factors

7.5.4.2 Selection of number of cells (cell type) and end voltage point

7.5.4.3 Cell Selection

1.) Calculate system demand with reference to battery charger efficiency and battery load
adjustment:

48VDC-1 Battery Bank has a demand load of 1,500 Watts.

1,500 Watts ÷ 0.90 = 1,666.67 Watts – Charger efficiency as per PMI Charger manufacturer >80% at
full load, say 90% efficiency.

As a recommendation we shall consider the factors suggested: Aging Factor: 125%

Design Margin: 105% (assumptions)
Temperature Correction Factor (k): 1.056, assuming temperature drops from 25°C to 20°C
(See Table-1: Temperature correction factor)

Adjusted Battery Load = 1,666.67 Watts x 1.25 x 1.05 x 1.056

Adjusted Battery Capacity = 2,310.00 Watts

2.) Calculate number of cells and end voltage:

With Reference to IEEE 1184, Guide for Batteries for UPS Systems.

With reference to Jiangsu Oliter Battery Model LCPC 250-12 Gel Battery:
It has a nominal capacity of Nominal capacity of 250Ah (10hr to 1.8VPC at 25ºC, Rated Voltage: 12V)
At 60 VDC maximum rectifier equalizing voltage (as per charger setting) and max charge 2.45VPC (6
cells/battery)

60VDC ÷ 2.45VPC = 24.4 Cells or 24 Cells; 6 Cells/battery = 4 Batteries

At 40VDC minimum voltage cut-off

Minimum Charger Voltage ÷ Number of Cells

40VDC ÷ 24 Cells = 1.67VPC

1 Battery unit has 6 cells, Therefore, 1.67VPC x 6 Cells = 10.02 Volts (End of discharge Voltage)

With reference to calculation Jiangsu Oliter LCPC 250-12 Gel Battery Model Unit has a minimum of 1.67
End of discharge voltage (EOV) per cell.

2.) Calculate cell performance as per adjusted battery load:

2,310.46 Watts ÷ 24 Cells = 96.25 Watts / cell (for this battery model unit as per calculation

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3.) Calculate battery current discharge as per adjusted battery load:

2,310.46 Watts ÷ 40.08VDC = 57.64 Amperes, at 1.67 Volt battery nominal voltage per cell at full load.

Referring to Jiangsu Oliter Battery Model LCPC 250-12, it has a 60.35 Amps for 3 hours
battery back-up operating time

With reference to IEEE Std 1115-2000, Annex A, Duty Cycle:

Battery Bank 48VDC connected loads duty cycle:

Period Connected Loads Total Amperes Duration (mins) Capacity (Ah)

1 RTU Panel 10.42 180 31.26 Note:
2 Radio Panel 10.42 180 31.26
See DB-48VDC
3 Spare 10.42 180 31.26
Panelboard Load
31.26 Total 93.78
Schedule for
connected loads.

Total Ampere-hour of LCPC 250-12 (12V at 250Ah): 60.35 Amperes for 3-hours or 181.05 Ah

Battery model LCPC 250-12 with 60.35 Ampere discharge (181.05 Ah) battery capacity for 3 hours is
sufficient for 48VDC system continuous connected loads.

Therefore, 181.05 Ah > 118.75 Ah – OK

Float Voltage: 2.275VPC x (6 cell / battery) x 4 batteries = 54.60 Volts, see Jiangsu Oliter Battery
Catalogue

Therefore, use 4 units Jiangsu Oliter Energy Technology LCPC 250-12 Battery Model for 48VDC-1

Phase-2 (Typical to 48VDC-2 – Power supply back-up)

Note:
Computation for 48VDC-1 & 2 Phase-2 is the same as the computation done for 48VDC-1 & 2
Phase-1

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Uninterruptible Power Supply (UPS-230VAC)

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Battery Bank UPS-230VAC:

With reference to the previous computations for Battery Bank 125VDC-1 & 2 & 48VDC-1 & 2:
1.) Calculate system demand with reference to battery charger efficiency and battery load
adjustment:

With reference to IEEE Std 1184

Guide for Batteries for Uninterruptible Power Supply Systems (Criteria):

UPS-230VAC Battery Bank has a demand load of 5,550 Watts.

UPS output in volt-amperes = 5,640 Watts ÷ 0.8pf = 6,9375.5 Volt-Amperes, or 10kVA UPS Capacity

5,550 Watts ÷ 0.90 = 6,166.67 Watts – UPS efficiency as per PMI Industries manufacturer >85% / 90%
depending on DC bus voltage, say 90% efficiency.

As a recommendation we shall consider the factors suggested: Aging Factor: 125%

Temperature Correction Factor (k): 1.056, assuming temperature drops from 25°C to 20°C
(See Table-1: Temperature correction factor)

Adjusted Battery Load = 6,166.67 Watts x 1.25 x 1.056

Adjusted Battery Capacity = 8,139.99 Watts

2.) Calculate number of cells and end voltage:

With reference to SEC Microlyte Battery Model 12-MRT-275:

It has a nominal capacity of Nominal capacity (Ah) C/10, 1.75VPC and float voltage of 2.25VPC ± 1% at
25ºC.

UPS Inverter has a nominal DC Voltage of 125VDC maximum rectifier equalizing voltage (as per charger
setting) and max charge 2.25VPC – For Battery charging…

125VDC ÷ 2.25VPC = 55.55 Cells or approximately 6 cells per Battery unit.

55.55 Cells ÷ 6 Cells / battery = 9.25 batteries or approximately 10 battery units (60 cells)

As per SEC Battery Microlyte Model Unit, it has a 1.67, 1.75 & 1.80 End of discharge voltage (EOV).

3.) Calculate cell performance as per adjusted battery load:

9,944.0 Watts ÷ 60 Cells = 165.73 Watts / cell

With reference to SEC Microlyte Battery Model 12-MRT-275, it has a Power performance of 172 Watts per
cell for 2 hour battery back-up time.

4.) Calculate battery current discharge as per adjusted battery load:

8,140.00 Watts ÷ 125VDC = 65.12 Amperes, at 1.75V battery end voltage per cell (recommended).

Referring to SEC Microlyte Battery Model 12-MRT-275, it has a 89.60 Amperes at 2-hour discharge time

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With reference to IEEE Std 1115-2000, Annex A, Duty Cycle:

Battery Bank 125VDC2 connected loads duty cycle:

Period Connected Loads Total Amperes Duration (mins) Capacity (Ah)

1 Workstation & printers 20.08 180 60.24
2 Network Server & FACP 25.60 180 76.80
3 PCB 7.344 10s (0.333 mins) 0.040759
4 Lighting, Weather Stn , RTCC, 6.54 180 19.62
59.564 Total 156.70

Note:
Current values in the table above are calculated in 125VDC voltage since UPS charger uses 125VDC
Rectifier/Inverter to charge and supply to the batteries and connected load respectively.

Total Ampere-hour of SEC Microlyte 12-MRT-275: 89.60 Amperes for 2-hours or 179 Ah, see SEC catalogue.

In relation to Ampere-hour (Ah) load duty cycle of 156.70 Ah,

Battery model 12-MRT-275 with 64.80 Amps battery capacity for 3 hours is sufficient since MVSG motors
operate intermittently.

Therefore, 194 Ah > 90.48 Ah – OK

Float Voltage: 2.25VPC x (6 cells / battery) x 10 batteries = 135 Volts, see SEC Microlyte Battery catalogue

Therefore, Use 10 units SEC 12-MRT-275 Battery Model for UPS-230V

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Battery Bank Chargers & UPS

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With reference to Power Management Instruments Battery Chargers (PMI):

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Charger for Battery Bank 125VDC-1:

Total Connected Load: 2,360 Watts

Demand Load: 2,158.61 Watts
Adjusted Battery Capacity: 2,849.37 Watts
Battery Current after Adjustment: 26.38 Amps
Demand Load Current Requirement: 15.54 Amps
Battery Current Discharge (3-hours): 64.80 Amps (Selected model 12-MRT-275)

Thus, use the following Charger / Inverter specification in accordance to the calculated values for Battery
Bank 125VDC-1:

RDA 110-100:
Vin: 220 (Ph-N)
VDCout: 110 VDC (0-160VDC)
Output Current: 100 Amperes (0-100%) > 64.80 Amps (Battery discharge current)

For Worst Case Input Current Computation (Over-current Protective Device),

See Low Voltage System Computation (Overcurrent Protective and Minimum Circuit Ampacity).

Charger for Battery Bank 125VDC-2:

Total Connected Load: 3,820 Watts

Demand Load: 2,720 Watts
Adjusted Battery Capacity: 3,989.33 Watts
Battery Current after Adjustment: 31.914 Amps
Demand Load Current Requirement: 21.76 Amps
Battery Current Discharge (3-hours): 64.80 Amps (Selected model 12-MRT-275)

Thus, use the following Charger / Inverter specification in accordance to the calculated values for Battery
Bank 125VDC-2:

RDA 110-100:
Vin: 220 (Ph-N)
VDCout: 110 VDC (0-160VDC)
Operational Output Current: 100 Amperes (0-100%) > 64.80 Amps (Battery discharge current)

For Worst Case Input Current Computation (Over-current Protective Device),

See Low Voltage System Computation (Overcurrent Protective and Minimum Circuit Ampacity).

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Charger for Battery Bank 48VDC (P2):

Total Connected Load: 1,500 Watts

Demand Load: 1,500 Watts
Adjusted Battery Capacity: 2,310.00 Watts
Battery Current after Adjustment: 48.125 Amps
Demand Load Current Requirement: 31.25 Amps
Battery Current Discharge (3-hours): 60.35 Amps (Selected model JIANGSU OLITER LCPC 250-12)

Thus, use the following Charger / Inverter specification in accordance to the calculated values for Battery
Bank 48VDC (P1):

RDA 48-200:
Vin: 220 (Ph-N)
VDCout: 48 VDC (0-60VDC)
Operational Output Current: 100 Amperes (0-100%) > 72.08 Amps

For Worst Case Input Current Computation (Over-current Protective Device),

See Low Voltage System Computation (Overcurrent Protective and Minimum Circuit Ampacity).

Note:

This reference for 48VDC-1 is typical to 48VDC-2 charger

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Uninterruptible Power Supply (UPS-230VAC):

Total Connected Load 7,540 VA

Demand Load: 5,550 VA
UPS Capacity: 10,000 VA or 10.0 kVA
Adjusted Battery Capacity: 8,139.99 Watts
Battery Current after Adjustment: 65.11 Amps
Battery Current Discharge (2-hours): 89.60 Amps

Thus, use the following UPS specification in accordance to the calculated values for Battery Bank for UPS-
230VAC System:

PMI Industrial UPS System KGK Series:

Rectifier Nominal Input Voltage: 230VAC
Power Range: 1-Phase, 10kVA
Rectifier Nominal DC Voltage: 125VDC
Rectifier Nominal DC Current: 100 Amps (0-100)
Inverter Nominal Input Voltage: 125VDC
Inverter Nominal Output Voltage: 230VAC
Operational Output Current: 100 Amps, 1-Phase (0-100%) > 65.11 Amps

For Worst Case Input Current Computation (Over-current Protective Device),

See Low Voltage System Computation (Overcurrent Protective and Minimum Circuit Ampacity).

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