March 17, 2020

March 17, 2020

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

TABLE OF CONTENTS

1.0 SCOPE

2.0 DC SYSTEM PARAMETERS

3.0 CELL SELECTION AND APPLICATION

3.1 General
3.2 Cell Design
3.3 Cell Selection Criteria

4.0 CELL SIZING DESIGN CRITERIA

4.1 General
4.2 Number of Cells
4.3 Charging Rate
4.4 Other Considerations
4.5 Duty Cycle
4.6 Cell Sizing Calculations

5.0 BIBLIOGRAPHY

APPENDIX – I Lead Acid Battery and Nickel Cadmium Battery Sizing Calculation
for Typical Substation

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TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

1.0 SCOPE

1.1 This Engineering Standard establishes general guidelines, parameters and design
criteria for the selection and sizing of lead acid and nickel cadmium storage batteries
intended to be used in the system of National Grid SA.

1.2 The text includes methods for defining loads and factors relating to cell selection to
ensure adequate battery capacity for specific applications.

2.0 DC SYSTEM PARAMETERS

Generally, the following parameters as specified in TES-P-119.02 are adopted for the DC
control systems in National Grid SA substations:

 Nominal DC system voltage : 125 V

 Allowable minimum DC system voltage : 101.5 V

based on 1.75 V end-of-discharge
voltage per cell for lead acid and 1.1 V
for nickel cadmium battery

 Allowable maximum DC system voltage : 135.14 V

based on 2.33 V maximum equalizing
voltage per cell for lead acid battery

Note: The maximum equalizing voltage is taken as 1.6 volt per cell for Nickel Cadmium
Ni-Cd battery, maximum load voltage to be limited to 135.14 V by dropper diodes in the
charger.

Float charging voltage per cell : Generally, 2.15 V - 2.25 V for Lead
Acid batteries and 1.38 V - 1.42 V for
Nickel Cadmium batteries, for accuracy
it shall be based on manufacturer's
recommendation of specific
battery to be used.

Grounding : Ungrounded system

3.0 CELL SELECTION AND APPLICATION

3.1 General

The cell selection of a storage battery is dependent upon the application and its
expected performance. The DC system design considers float battery operation with
battery charger serving to maintain the battery in a fully charged condition as well as
to supply the normal DC load. The batteries are put in equalizing mode without
disconnecting the batteries or the DC load from the bus. At the time of equalizing, all
the connected DC equipment is subjected to the maximum voltage of 135.14 V.

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Several basic factors govern the size (number of cells and rated capacity) of the
battery. Included are the maximum system voltage, the minimum system voltage, the
duty cycle, correction factors, and design margin. Because a battery string is usually
composed of a number of identical cells connected in series, the voltage of the
battery is the voltage of a cell multiplied by the number of cells in series. The
ampere-hour capacity of a battery string is the same as the ampere-hour capacity of a
single cell.

In general, cell selection shall be made with the objective of meeting the load
requirements using the most economical battery which has long life and requires
minimum maintenance.

The Lead Acid batteries being economical, having high overcharge tolerance, less
self-discharge, low maintenance requirements (may be in the form of equalizing or
topping charge) and less toxic when compared with Nickel Cadmium batteries, shall
be used. Moreover, Nickel cadmium can also be a choice.

3.2 Cell Design

a. For Lead Acid cells, the positive plate configuration is either of the three
categories :

 Plante and/or modified plante

 Tubular

 Flat plate (pasted)

The negative plates are always of flat plate design.

Classification according to cell material falls into pure lead (plante), lead
antimony and lead calcium alloys. The lead alloys compositions are however,
mostly used in National Grid SA system.

Latest hybrid systems of alloys which offer longer l ife and less maintenance can also be
applied as per NG approval.

b. Nickel cadmium use an alkaline electrolyte (potassium hydroxide). The active

materials are nickel hydroxide in the positive plate and cadmium hydroxide in
the negative plate. Several design of vented nickel cadmium batteries are
available depending on plate construction. The most commonly used designs are
the pocket plate, the fiber plate, the sintered plate and the plastic bonded plate.

3.3 Cell Selection Criteria

3.3.1 General

a. Load Requirements
b. Expected Life of the Cell and Planned life of the installation

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c. Ambient Temperature
d. Maintenance Requirements
e. Physical Characteristics such as dimension and weight of the cells,
container material, inter cell connectors, and terminals
f. Economic Considerations
g. Charging characteristics
h. Frequency and depth of discharge
i. Ventilation requirements
j. Shock and vibration

3.3.2 Cell performance may largely affect its selection. A comparison of lead acid
cell performance characteristics based on material composition and plate
design is highlighted in Table 1 and Table 2, respectively.

Table 1: Cell Performance Characteristics Based on Material Composition

Type of Plate Material Recovery from Water Service Integrity Initial Cost
Cell Composition Cyclic Consumption Life and
Operations in Years Reliability
Pure lead Withstands Low, 20-25 Excellent High, offering
(plante) frequent cycling increases cost effective
with age long term
Lead capability
Acid Lead- Withstands Frequent, 15-20 Good Moderate
antimony frequent cycling increases
with age
Lead- Not suitable for Low 15-20 Good Moderate
Calcium deep discharges
Nickel Nickel Withstands High 20-25 Excellent Very High
Cadmium Cadmium frequent cycling

Note: Lead calcium positive plates may grow in length and width because of grid oxidation
at the grain boundaries. This oxidation is usually caused by long term overcharging which is
common to batteries on constant float Grids may grow in size sufficiently to cause buckling
or rupture of their containers. Lead calcium plate batteries are not recommended for use in
National Grid SA system.

Table 2: Performance Characteristics Based on Plate Design

Type of Plate Energy Output Resistance to Cyclic Initial Cost
Design Anodic Corrosion Application
Plante High, long term High Suitable High
capacity
Lead Acid Tubular Moderate, long Moderate Suitable Moderate
discharge rate
Pasted (flat) High, short Low Less suitable Less
discharge rate
Nickel Pocket Type Good for High Low Excellent Very High
Cadmium discharges

3.3.3 High ambient temperatures above 25 °C (77 °F) result in reduced life due to
accelerated chemical reaction. As a general rule of thumb, for every 9°C (15°F)
increase in electrolyte temperature above 25°C (77°F), the cell life is halved.

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3.3.4 Nickel cadmium, and other approved new technology batteries can sustain high
temperature more easily than the lead acid ones.

4 CELL SIZING DESIGN CRITERIA

4.1 General

4.1.1 The number of cells and rated capacity, is primarily determined by the
following three (3) factors.

a. Maximum System Voltage

b. Minimum System Voltage
c. Duty Cycle

4.1.2 Conditions such as ambient temperature, discharge rate and final cell voltage
directly influence the available cell capacity. Hence, it is imperative that cell
capacity (expressed in ampere hours - Ah) shall always relate to the standard
conditions specified in 46-TMSS-01 for Lead Acid and 46-TMSS-06 for
Nickel Cadmium batteries and reproduced as under:

a. 8 or 10 hours discharge rate (capacity inversely related to discharge rate)

b. 25°C (77°F) ambient temperature (low temperature reduces available
capacity and higher temperature increases the available capacity
particularly for lead acid battery)
c. Electrolyte specific gravity at 25ºC, 1.215 to 1.263 for vented lead-acid
and 1.16 to 1.25 for nickel cadmium cells.
d. End-of-discharge voltage per cell as 1.75V for vented Lead-acid and 1.1V
for vented Nickel Cadmium cells (minimum cell voltage limits the Ah
capacity).

4.1.3 Data acquired or calculations made to non-standard conditions shall be

corrected for standard conditions.

For Lead Acid cell sizing temperature correction factors, refer to Table 4
extracted from IEEE Std. 485 and for discharge current temperature
correction factors, reference shall be made to IEEE Std. 450.

For Nickel Cadmium cell, reference shall be made to IEEE 1115 and the
battery manufacturer’s data should be consulted for capacity derating factors
for various discharge time and electrolyte temperatures. If the expected
electrolyte temperature is above 25ºC, generally there is no noticeable
increase in the available capacity.

4.1.4 The Ampere-hour capacity of the entire battery bank shall be same as that of
a single cell which depends on the size and number of plates. Parallel
connections of low capacity cells to obtain the specified capacity is not
permissible.

4.1.5 The battery shall have 100% capacity upon delivery.

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4.2
4.3 Number of Cells

The number of cells is influenced by the maximum and minimum system voltages as
follows:

a. The number of cells governed by maximum system voltage as per IEEE 1818
Clause 5.2.5.4 Equation 14 is defined as:

(1)

b. The number of cells satisfying minimum system voltage is defined as:

Minimum System Voltage

No. of cells =
End - of - Discharge Voltage per Cell (2)

Both the abovementioned formulas can be used for Lead Acid battery while for
Nickel Cadmium battery only formula (2) is applicable.

Based on the voltage window 101.5 V- 135.14 V as specified in clause 2.0 and lead
acid battery with equalizing voltage 2.33 V per cell, SEC has standardized 58 battery
cells for 125 V nominal DC system voltage.

For 125 V DC system voltage with Nickel Cadmium battery bank, considering the
minimum system voltage of 101.5 V and end of discharge voltage as 1.1 V, the
number of nickel cadmium cells shall be calculated on case to case basis as per
required nominal and permissible minimum and maximum DC system voltages and
in the light of self-discharge and charging time as limiting factor, which may result
in using larger cell that would otherwise have been necessary (Refer IEEE 1115).
Dropping diodes may be used in the circuit to avoid overvoltage beyond permissible
limits as indicated in 46-TMSS-02.

4.4 Charging Rate

The specified recharge time influences the cell size. Hence, the number of cells and
size shall be selected so as to be recharged to 100% capacity within the
specified/available time shown in Table 3 for different applications.

Table 3: Charging Rate for Different Battery Applications

Battery Application Recharge
(Hours)
Substations 16
Uninterruptable Power Supply 8

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4.5 Other Considerations

The following factors also influence the final choice of the cell size; hence these
must be duly taken into account during the course of calculations.

4.4.1 Temperature Correction Factor (Kt)

High temperature accelerates the chemical reactions, thus increases the cell
capacity and decreases the expected life. The converse is true for low
temperatures. The standard temperature for stating cell capacity is 25°C
(77°F) as specified in clause 4.1.2. If the cell temperature is expected to be
less than 25°C (77°F) the cell size shall be adequately increased by
multiplying with the correction factor indicated in Table 4.

For SEC applications, generally the battery sizing calculations shall be done
at an assumed cell temperature of 10ºC (50ºF) which corresponds to
temperature correction factor of 1.19 for lead acid battery.

Table 4: Temperature Correction Factors (Kt)

Electrolyte Cell Size Electrolyte Cell Size
Temperature Correction Temperature Correction
(°F) (°C) Factor (°F) (°C) Factor
25 - 3.9 1.523 80 26.7 0.98
30 - 1.1 1.43 85 29.4 0.96
35 1.7 1.35 90 32.2 0.94
40 4.4 1.30 95 35.0 0.93
45 7.2 1.25 100 37.8 0.91
50 10.0 1.19 105 40.6 0.89
55 12.8 1.15 110 43.3 0.88
60 15.6 1.11 115 46.1 0.87
65 18.3 1.08 120 48.9 0.86
70 21.1 1.04 125 51.7 0.85
77 25 1.0 - - -

4.4.2 Design Margin Factor (Kd)

This factor compensates for unforeseen future load additions in the DC

system. A factor of 1.1 shall be used. For future load it shall be as per SOW,
if not stated and addition shall be done, new sizing calculation shall be
provided.

4.4.3 Aging Factor (Ka)

Capacity decreases gradually during battery life cycle. Aging factor allows
the battery to meet its duty cycle as it reaches the end of its expected life. A
factor of 1.25 for Lead Acid and Nickel Cadmium batteries shall be used.

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The battery is thus sized to carry the load until the capacity has decreased to
80% of its rated capacity.

In extreme case of continuous high temperature and frequent deep discharge

it may be desirable to use the aging factor 1.43 for nickel cadmium. The
battery shall be replaced when its capacity falls to 70% of rated capacity.

4.6 Duty Cycle

4.5.1 General

Duty cycle is defined as the load currents a battery is expected to supply for
specified time periods under specific modes of application. It, therefore,
requires that each load be correctly assessed and identified as to its inception
and duration. Sizing of a cell is based upon the duty cycle. Therefore, careful
development of duty cycle is the key to proper sizing.

4.5.2 Load Requirements

The load requirements shall be classified into the following categories:

a. Continuous Loads

These loads initiate at the very inception of the duty cycle and remain
energized throughout the duty cycle period. Typical loads include:

i. Indicating lights
ii. Lighting
iii. Continuously operating motors
iv. Converters (e.g., inverters, dc-dc converters)
v. Communication systems
vi. Microprocessors and computer devices
vii. Annunciation/alarm systems
viii. Continuously energized coils
ix. Other continuous loads

The battery shall be sized to feed these continuous loads for the full
durations of battery discharge as indicated in Table 5 below.

Table 5: Discharge Periods for Different Battery Applications

Battery Application Discharge (Hours)
Substations 10
Uninterruptible Power Supply 1

Note: For remote substations, more than 100 kM area from city if not
specified in the PTS the discharge duration shall be 14 hours.

b. Non-Continuous Loads

i. Emergency Loads
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These loads may be initiated any time during duty cycle and are supplied
for a particular period of time. These loads may be categorized as :

 Emergency lighting
 Emergency motors
 Fire protection systems actuations
 Motor-driven valve operations (stroke time >1 minute)
 Critical ventilation system motors

The duration of Emergency loads shall be taken as three (3) hours.

ii. Momentary Loads

These are non-continuous loads of short duration not exceeding one(1)

minute. These loads can occur repeatedly during the duty cycle and are
considered coincident with highest load requirement. Typical momentary
loads include:

 Switchgear operations
 Motor-driven valve operations (stroke time <1 minute)
 Isolating switch operations
 Field flashing of generators
 Motor starting currents
 Inrush currents
 Other Loads

Loads that occur at any time in a duty are termed "Random" loads. These
may be either non-continuous or momentary. These loads are however
not considered for sizing battery in National Grid SA applications.

4.5.3 Duty Cycle Profile

a. Once the duty cycle loads are correctly identified and tabulated, a duty
cycle profile based on these loads can be subsequently developed
showing the anticipated inception and shutdown times. Such a graphical
representation of all possible load combinations and variations helps in
better analysis of battery duty cycle.

b. Although, the actual cell sizing is a simple mathematical procedure,

effective sizing is largely dependent upon the proper development of the
duty cycle profile. The following special considerations shall be taken
into account:
i. Momentary loads shall be assumed to last one full minute even
though they may actually last for only a fraction of a second,
because the instantaneous battery voltage drop for a given
momentary load is essentially the same as the voltage drop after one
minute (Reference IEEE 485 & IEEE 1115).

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ii. As regards the determination of the momentary loads, these shall be

taken as the sum of all loads occurring within a minute unless a
discrete sequence can be established. If a discrete sequence is
established, the momentary load will be the maximum current
occurring during the minute.

iii. Loads with indefinite shut down times shall be assumed to continue
through the rest of the duty cycle.

iv. Random loads, if any, shall not be considered in the initial

calculations. These loads shall be super imposed subsequently on
the most critical section of the duty cycle so determined, to simulate
worst case condition.

4.7 Cell Sizing Calculations

4.6.1 The following cell sizing calculations methods for lead acid and nickel
cadmium battery are based on IEEE standard 485 and IEEE 1115
respectively. A specially developed Work Sheet with example of its use is
also included to facilitate the calculation process. Figure 1 illustrates a
generalized duty cycle profile for foregoing discussions. The method is a
simple iterative technique wherein each section of duty cycle profile is
individually analyzed. If the current in succeeding section say N+1 is greater
than the current in preceding section N, no sizing calculations is required for
section N since section N+1 will always require a larger battery than section
N.

Figure 1. Generalized Duty Cycle Diagram

4.6.2 The formulas for sizing both lead acid and nickel cadmium batteries are
given below:

Lead acid cell sizing (positive plate method):

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S=N S N P=S A P  A P 1

max FS  max
S1
S=1
P=1 RT
(3)

Lead acid cell sizing (ampere-hour method):

max FS  max  A P  A( P 1)  KT

S=N S N P=S

S 1
S=1 P=1 (4)

Nickel-cadmium cell sizing:

 A  A( P 1) K t Tt
S= N S N P =S
max FS  max P (5)
S=1 S1 P =1

Where,

AP Current for period P

FS Uncorrected cell size
KT Ratio of rated ampere-hour capacity (at standard time rate at 25ºC and
to a given end of discharge voltage) of a lead acid cell, to the amperes
that can be supplied for T minutes at 25ºC, and to a given end of
discharge voltage. This factor is used for sizing based upon AH
capacity and shall be obtained from the actual performance
curves/data of the manufacturer
Kt Capacity rating factor for a given nickel cadmium cell type, at the t
minutes discharge rate at 25ºC, to a definite end of discharge voltage
(As the nickel cadmium cell in National Grid SA will be constant
potential charged, the capacity rating factor used shall be based upon
constant potential charging)
N Number of periods in the duty cycle
P Period being analyzed
RT Number of amperes that each positive plate can supply for T minutes
at 25C to a definite end of discharge voltage for a lead acid cell.
S Section of duty cycle being analyzed
T, t Time in minutes from the beginning of period P through the end of
section S for lead acid and nickel cadmium cells respectively
Tt Temperature derating factor for nickel cadmium cell at t minutes ,
based on the electrolyte temperature at the start of the duty cycle

As a result of above computations, section requiring the largest battery is

selected and the final cell size is then calculated by applying correction
factors discussed in clause 4.4.

For lead acid cell:

F  (max FS)Dt Kd Ka (6)

For nickel cadmium cell:

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F  (max FS)Kd Ka (7)

Where,

F Required final cell size

Ka Aging factor
Kd Design margin factor
Dt Temperature correction factor

4.6.3 Any fractional cells computed as a result of calculations, shall be rounded off
to nearest whole number.

The cell size thus finally calculated shall be the optimum size for specific
application and shall have enough capacity to carry the combined loads
during the duty cycle.

The cell size thus selected usually does not match with the commercially
available sizes. Under this situation, the next higher capacity cell shall be
selected which further introduces additional degree of conservatism in cell
sizing calculations.

4.6.4 Attached herewith as Appendix-I are based on study of NG sizing

calculations for Lead acid battery and Nickel Cadmium. For 110/13.8kV,
115/ 13.8 kV or 132/13.8 kV substations with 12 bays, 3 x 50/67 MVA
Power Transformers and 3 Sections of 13.8 kV Switchgears. Sample is
provided only as a calculations guide, and for individual projects it shall be
verified based on actual load requirements.

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5.0 BIBLIOGRAPHY

1. IEEE 100 Standard Dictionary of Electrical and Electronics Terms

2. IEEE 446 Recommended Practice for Emergency and Standby Power

Systems for Industrial and Commercial Applications.

3. IEEE 450 Recommended Practice for Maintenance, Testing and Replacement of

Vented Lead Acid Storage Batteries for Stationary Applications.

4. IEEE 484 Recommended Practice for Installation Design and Installation of

Vented Lead Acid Storage Batteries for Stationary Applications.

5. IEEE 485 Recommended Practice for Sizing Lead Acid Batteries for Stationary
Applications.

6. IEEE 1115 Recommended Practice for Sizing Nickel Cadmium Batteries for
Stationary Applications

7. IEEE 1106 Recommended Practice for Installation, Maintenance, Testing and

Replacement of Nickel Cadmium Batteries for Stationary
Applications

8. IEEE 1184 IEEE Guide for the Selection and Sizing of Batteries for
Uninterruptible Power Systems

9. IEEE 1818 IEEE Guide for the Design of Low-Voltage Auxiliary Systems for
Electric Power Substations

10. IEEE 1189 IEEE Guide for Selection of Valve-Regulated Lead-Acid (VRLA)
Batteries for Stationary Applications

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TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

APPENDIX - I

LEAD ACID BATTERY and NICKEL CADMIUM BATTERY SIZING CALCULATIONS

FOR 110/13.8kV, 115/13.8kV, 132/13.8kV SUBSTATIONS

1.0 GENERAL

The provided sample calculations basically are for battery size of 132kV, 115 kV, and 110
kV Unified substations based on recommendations by National Grid SA study comprising of
12 bays details highlighted in the appendix. This is only a sample that will serve as a
calculation guide in determining the requirements, however to calculate the exact project
requirements actual project data shall be applied.

An assumed summary of the equipment-wise load is indicated in section 4, below. The load
profile thus developed (refer to section 6) based from the Unified Substation arrangement
fairly depicts the load requirements for sizing the most economical battery.

2.0 DESIGN SIZING CRITERIA FOR LEAD ACID BATTERY

Battery sizing is based on the following criteria:

2.1 Required number of cells:

Nominal DC voltage = 125V

Allowable maximum DC voltage = 135.14 V
Allowable minimum DC voltage = 101.5V
Lead Acid Battery Equalizing voltage = 2.33 V

The condition applied is that battery and charger are continuously connected to the
loads.

Using equation Eq.1, as per above Clause 4.2

Number of cells = 135.14 / 2.33 = 58 cells

Using equation 2, as per above clause 4.2 of standards:

Minimum System Voltage

No. of cells =
End - of - Discharge Voltage per Cell

Wherein:

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101.5
End of discharge voltage =  1.75 V/cell
58

2.2 The duration of continuous loads is taken as 10 hours in general. The duration of
other loads is based on National Grid SA practice/design criteria. However, for
remote substations the working committee/engineer who finalizes the PTS for the
concerned project, will decide the duration of continuous load.

2.3 Normally the battery room temperature is maintained at 25°C. Standardization takes
into account the following factors :

• Temperature correction factor of 1.19 based on inside room temperature of 10

°C in case of power failure.

• Design Margin factor of 1.1.

• Aging factor of 1.25.

2.4 Worst contingency case for assessing the momentary loads takes into consideration
the following assumptions:

a. Simultaneous tripping of one (1) Line and one (1) Transformer which involves
tripping of four (4) HV breakers.

b. The simultaneous bus fault on both 13.8 kV buses, which calls for tripping of 30
Nos. 13.8 kV breakers; via the simultaneous operation of bus differential
protection. It is also assumed that either one of the outer bus sections acts as a
standby.

c. At the time of restoration, the following simultaneous operations are assumed.

• Closing of one breaker (Even if it is assumed that the mechanism of one breaker
fails, the second breaker will be closed after the failure of the first. The total
momentary load will be one after another and will not be for more than one
minute).

• Simultaneous closing of one incomer, and one outgoing feeder (controlling the
station service transformer) and tripping of one breaker if fault persists. It also
considers that one spring charging motor is in the process of starting and one
motor is running.

2.5 Starting current of spring charging motor is taken as 5 times the normal current.

2.6 DC load assessment does not include emergency exit lights and other lights which are
equipped with self-contained rechargeable battery packs.

2.7 DC emergency lights fed from the battery are:

a. manually switched on by the maintenance personnel who reach the substation
within 3 hours of power failure
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b. a maximum number of 20 lights are switched on at any given time

c. lights will be on for 3 hours

2.8 Actual cell sizing is shall be based on Performance curves/data of one of the Listed
manufacturers.

3.0 SCOPE

The Unified 12 bays 110/13.8 kV or 115/13.8 kV or 132/13.8kV substation has the

following scope of work based on standard one line diagram.

3.1 110 kV/115 kV/132kV Switchgear comprising of the following:

Six (6) lines and three (3) 50/67 MVA Power Transformers, details are below;

3 - Power Transformer Circuit Breakers

6 - Feeder Breakers
2 - Bus coupler
1 - Bus Section

3.2 Three Sections of 13.8 kV Switchgear comprising of the following:

3 - Incoming Transformer Feeders

38 - Outgoing Metered feeders
2 - Bus Tie & Bus Riser
2 - Auxiliary Transformer Feeder
3 - Capacitor Feeders

4.0 DC LOAD DETAILS

Table 6: Summary of the Equipment-wise DC Load Assessment

Continuous Load Momentary Load
Description Quantity (W) (W)
Unit Total Unit Total
a) Protection Load 3414 -
b) 115 kV Switchgear 3468
c) 13.8 kV Switchgear Panels
Circuit Breaker
. Trip/closing coil each 250
. Motor 300 2450
d) Emergency Loads Lights 20 60 1200
e) SCADA/SAS Load 4150
f) Communication Load 4941
g) Transformer Load 2012
i) Any other load relevant to
Typical substation

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TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

Table 7: Area Tabulated Summary of DC Load Assessment as per Unified Study

Final
LOADS (Watts)
EQUIPMENT Considered REMARKS
COA WOA EOA SOA Loads
HICO Unified Purchase
contract for 12 Bays
GIS (HICO) + BCU 3288 3288 3288 3060 3468 (BCU Load considered
=50W) 2868 + (12x50)
=3468W
As per Military City 2
13.8 kV Swgr 2249 3893 2252 2445 2445
Substation Load
Provided by Telecom
Telecom Load 2012 6661 1020 1663 4941
Unification Committee
Provided by Telecom
SAS Loads 2846 2990 3587 2704 4150
Unification Committee
HICO Unified Purchase
Power T/F HICO 1548 2012 170 1500 2012 contract for 3
Transformers
Protection Loads As per Military City 2
3121 1789 2709 3414 3414
(AES) Substation Load
TOTAL 15064 20633 13026 14786 20430

Total Continuous Load = 20430/101.5 = 201.28 A

5.0 DC LOAD ESTIMATION

5.1 Total continuous load for 10 hours = 3414+ 3468 W + 2445

+ 4150 + 2012 = 20430 W
= 201.28 Amps

5.2 Emergency lighting load for 3 hours = 1200 W = 9.6 A

5.3 Momentary Loads for one (1) minute

a) Assuming simultaneous tripping of 30 nos. breakers, per clause 2.4 (b).

Trip coils load = 30 x 2450 = 73500 W = 588 A

b) At the time of restoration, per conditions simulated in clause 2.4.

Two breaker closing = 2 x 1 x 250 = 500 W

Two breaker tripping = 2 x 2 x 250 = 1000 W
Two motor starting = 2 x 5 x 300 = 3000W
Two motor running = 2 x 300 = 600W

Total = 5100 W = 40.8 A

6.0 DUTY CYCLE (D.C. LOAD PROFILE) & CELL SIZING CALCULATIONS:

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 18 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

6.1 Based upon above loads the duty cycle is drawn. It is to be noted that the duty cycle
does not include any spare capacity as this is accounted for by the design margin
factor (Kd).

6.2 The Duty cycle includes loads at the end of the cycle which are required for restart,
ensuring that there should be enough energy in the battery at the end of the duty
cycle to close the breakers upon restoration of AC supply.

The following data is summarized from the battery duty cycle:

a) Load Summary:

L1Continuous load for 10 hours = 201.28 A

L2Momentary Load for 1 minute = 588 A
L3Emergency Load for 3 hours = 9.6 A
L4Momentary Load for 1 minute = 40.8 A

b) Cell Sizing Data:

Period Loads Total amperes Duration(Minutes)

1 L1+L2 789.28 1
2 L1 201.28 179
3 L1+L3 210.88 180
4 L1 201.28 239
5 L1+L4 242.08 1

Figure 2. Battery Duty Cycle

Capacity Rating Factor KT:

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 19 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

KT factors used for calculation are tabulated as below. The actual KT factors shall be
obtained on the basis of the suppliers’ curve for the respective battery:

T Minutes KT Factor T Minutes KT Factor

1 1.4686 360 5.3546
179 3.4585 419 5.9810
180 3.4647 420 5.9900
239 4.0830 598 8.5500
240 4.0940 599 8.5600
359 5.3443 600 8.5610

LEAD ACID BATTERY SIZING WORKSHEET

Note: Interpolation method was used to get the mid values for Kt factor (Y Company).
However, for more accurate results battery manufacturer shall be consulted for Kt and
Temperature factor values. It various from manufacturer to manufacturer.

Time to
Capacity
Change in Duration End Positive Negative
Period Load (A) Rating
Load of Period Section Values Values
Factor, Kt
(Min)
Section 1-First Period Only – if A2 is greater than A1, go
NO
to Section 2 - NO
A1=789. A1-
1 M1=1 T1=1 1.4686 1159.1366 0.00
28 0=789.28
Total 1159.1366

Time to Capacity
Change in Duration of Positive Negative
Period Load (A) End Rating
Load Period Values Values
Section Factor, Kt
Section 2-First 2 Periods Only – if A3 is greater than A2, go to
YES
Section 3 - YES
A1-
1 A1=789.28 M1=1 T1+T2=180 3.4647 2734.6184 0.00
0=789.28
A2-A1=
2 A2=201.28 M2=179.00 T2=179.00 3.4535 0.00 -2030.66
-588.00
Sub Total 2735.1035 -2030.66
Total 703.9584

Time to Capacity
Change in Duration of Positive Negative
Period Load (A) End Rating
Load Period Values Values
Section Factor, Kt
Section 3-First 3 Periods Only – if A4 is greater than A3, go to
NO
Section 4 - NO
A1- T1+T2+T3
1 A1=789.28 M1=1 5.3546 4226.2787 0.00
0=789.28 =360.00
A2-A1= T2+T3=
2 A2=201.28 M2=179.00 5.3443 0.00 3142.4484
-588.00 359.00
3 A3=210.88 A3-A2=9.6 M3=180.00 T3=180.00 3.4647 33.2611 0.00
Sub Total 4259.5398 -3142.45
Total 1117.0898

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 20 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

Capacity
Change in Duration of Time to End Positive Negative
Period Load (A) Rating
Load Period Section Values Values
Factor, Kt
Section 4-First 4 Periods Only – if A5 is greater than A4, go to
YES
Section 5 - YES
A1- T1+T2+T3+T4
1 A1=789.28 M1=1 8.5600 6756.2368 0.00
0=789.28 =600.00
A2-A1= T2+T3+T4=
2 A2=201.28 M2=179.00 8.5500 0.00 -5027.4
-588.00 599.00
A3-
3 A3=210.88 M3=180.00 T3+T4=419.00 5.9810 57.4176 0.00
A2=9.6
A4-A3=
4 A4=201.28 M4=239.00 T4=239.00 4.0830 00 -39.1968
-9.6
Sub Total 6813.6544 -5066.5968
Total 1747.0576

Capacity
Change in Duration of Time to End Positive Negative
Period Load (A) Rating
Load Period Section Values Values
Factor, Kt
Section 5-First 5 Periods Only – if A6 is greater than A5, go to
YES
Section 6 - YES
A1- T1+T2+T3+T4
1 A1=789.28 M1=1 8.5610 6757.0261 0.00
0=789.28 =600.00
A2-A1= T1+T2+T3+T4
2 A2=201.28 M2=179.00 8.5610 0.00 -5033.868
-588.00 = 600.00
A3-
3 A3=210.88 M3=180.00 T3+T4=419.00 5.9900 57.504 0.00
A2=9.6
A4-A3=
4 A4=201.28 M4=239.00 T4+T5=240.00 4.0940 0.00 -39.3024
-9.6
A5-
5 A5=242.08 M5=1.00 T5=1.00 1.4686 59.9189 0.00
A4=40.8
Sub Total 6874.45 -5074.22
Total 1800.23

Selection of Lead Acid Battery Size:

Uncorrected Battery Size (max Fs) = 1800.23Ah

Temperature correction Factor Dt = 1.19
Design Margin Kd = 1.1
Aging Factor Ka = 1.25

Using equation 6, as per above clause 4.6.2:

F  (max FS)Dt Kd Ka (6)

Required Capacity = (max Fs) x Kd x Ka = 1800.23 x 1.1 x 1.25 x 1.19

= 2945.63 Ah (Nearest highest Capacity Ex. 2950 Ah)

Lead Acid Battery shall be selected as per the available Battery Manufacturers catalog’s
nearest highest capacity rating.

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 21 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

Figure 3. Hypothetical Composite Curve for X Cell by Y Company

7.0 DESIGN SIZING CRITERIA FOR NICKEL CADMIUM BATTERY

Battery sizing is based on the following criteria:

7.1 Required number of cells:

Nominal DC voltage = 125V

Allowable minimum DC voltage = 101.5V
End of Discharge voltage = 1.1 V/cell

The condition applied is that battery and charger are continuously connected to
the loads.

Using equation 2, as per above clause 4.2

Minimum System Voltage

No. of cells =
End - of - Discharge Voltage per Cell

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 22 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

Number of Cells = 101.5/1.1 = 92.27 ≈ 92 Cells

7.2 Similar assumptions applied with Lead Acid Battery for Scope, Conditions, DC
Load details and estimation, will be considered for Nickel Cadmium battery
calculations.

7.3 Duty Cycle (DC Load Profile) & Cell Sizing Calculations:

7.3.1 Based upon above loads the duty cycle is drawn. It is to be noted that the
duty cycle does not include any spare capacity as this is accounted for by the
design margin factor (Kd).

7.3.2 The Duty cycle includes loads at the end of the cycle which is required for
restart, ensuring that there should be enough energy in the battery at the end
of the duty cycle to close the breakers upon restoration of A.C.

The following data is summarized from the battery duty cycle:

a) Load Summary:

L1 Continuous load for 10 hours = 201.28 A

L2 Momentary Load for 1 minute = 588 A
L3 Emergency Load for 3 hours = 9.6 A
L4 Momentary Load for 1 minute = 40.8 A

b) Cell Sizing Data:

Period Loads Total amperes Duration(Minutes)

1 L1+L2 789.28 1
2 L1 201.28 179
3 L1+L3 210.88 180
4 L1 201.28 239
5 L1+L4 242.08 1

Duty Cycle is similar with the above Lead Acid

c) Capacity rating factors (Kt) for KM369P Cell Type

Kt factors used for calculation are tabulated as below for typical Nickel-
Cadmium cell referred in Table -10. The actual Kt factors shall be obtained on
the basis of the suppliers curve for the respective battery. Designer should make
sure that capacity rating factors (Kt) obtained from the manufacturer is based on
constant potential operation.

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 23 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

Table – 8
Discharge Time t1 Time t2 (1) (2) Factor Factor Factor
time t from from Amperes Amperes Kt1for Kt2for Kt for
(min) data data for time t1 for time t2 time t1 time t2 time t
(min) (min) (A) (A) 369 ÷ 369 ÷
(1) (2)
1 1 -- 627 -- 0.589 -- 0.589
179 120 180 138 107 2.67 3.45 3.44
180 180 -- 107 -- 2.05 -- 3.45
359 300 480 72.0 45.4 5.13 8.13 6.11
360 300 480 72.0 45.4 5.13 8.13 6.13
539 480 720 45.4 29.83 8.13 12.37 9.17
540 480 720 45.4 29.83 8.13 12.37 9.19
718 480 720 45.4 29.83 8.13 12.37 12.33
719 480 720 45.4 29.83 8.13 12.37 12.35
720 720 -- 29.83 12.37 12.37

d. Temperature Correction Factor (Tt)

Table -9
Discharge Temperature derating Discharge time (t) Temperature
time (t min) factor (Tt) at 10 °C correction factor (Tt) at
10 °C
1 1.1 539 1.04
179 1.05 540 1.04
180 1.05 718 1.04
359 1.04 719 1.04
360 1.04 720 1.04

Table - 10
Hypothetical discharge currents for KM cell range manufactured by ABC Company (Discharge
amperes to 1.1 V/cell after prolonged float charging)

Cell type Rated 1s 60 s 15 30 60 90 120 180 300 480 720

Ah min min min min min min min min min
KM369P 369 878 627 334 266 207 166 138 107 72.0 45.4 29.83
KM392P 392 927 666 355 282 220 177 147 113 76.4 48.2 31.69
KM415P 415 984 705 375 299 233 187 155 120 80.9 51.0 33.35
KM438P 438 1041 743 396 315 246 198 164 127 85.4 53.9 35.41
KM461P 461 1090 786 417 332 258 208 173 133 89.9 56.7 37.26
KM505P 505 1197 857 457 364 283 228 189 146 98.5 62.1 40.82
KM555P 555 1317 942 502 400 311 250 208 161 108 68.3 44.86
KM625P 625 1480 1062 565 450 350 282 234 181 122 76.9 50.52
KM690P 690 1635 1175 624 497 387 311 258 200 135 84.9 55.78
KM740P 740 1756 1260 669 533 415 334 277 214 144 91.0 59.82
KM830P 830 1968 1409 754 598 465 374 311 240 162 102 67.09
KM920P 920 2181 1565 833 663 516 415 345 266 179 113 74.37

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 24 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

The Kt factor for time t is calculated in the following table by interpolation using the
formula
K t  K t2 
 
K t 2  K t1  t 2  t 
t 2  t1 
Note that interpolation must be performed only on the Kt factors. Interpolation of current
will yield incorrect results.

Figure 4. Hypothetical Temperature Derating Curve for X Cell by Y Company

NICKEL CADMIUM BATTERY SIZING WORKSHEET

Time to Temperat
Capacity
Perio Change in Duration End ure Positive Negative
Load (A) Rating
d Load of Period Section Derating Values Values
Factor, Kt
(Min) Factor
Section 1-First Period Only – if A2 is greater than A1, go to
NO
Section 2 - NO
1 A1=789. A1- M1=1 T1=1 1.090 1.100 946.3467 0.00
28 0=789.28 Total 946.3467

Temperat
Time to Capacity
Perio Change in Duration ure Positive Negative
Load (A) End Rating
d Load of Period Derating Values Values
Section Factor, Kt
Factor

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 25 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

Section 2-First 2 Periods Only – if A3 is greater than A2, go

NO
to Section 3 - YES
A1=789. A1- T1+T2=18
1 M1=1 3.830 1.050 3174.09 0.00
28 0=789.28 0
A2=201. A2-A1= - M2=179.0
2 T2= 179 3.810 1.050 0.00 -2352.29
28 588.00 0
Sub Total 3174.09 -2352.29
Total N/A

Time Temperat
Capacity
Perio Change in Duration of to End ure Positive Negative
Load (A) Rating
d Load Period Sectio Derating Values Values
Factor, Kt
n Factor
Section 3-First 3 Periods Only – if A4 is greater than A3, go
NO
to Section 4 - NO
T1+T2
5138.528
1 789.28 A1-0=789.28 M1=1 +T3=3 6.260 1.040 0.00
5
60.00
T2+T3 -
A2-A1= -
2 201.28 M2=179.00 =359.0 6.240 1.040 0.00 3815.884
588.00
0 8
T3=18
3 210.88 A3-A2=9.6 M3=180.00 3.830 1.040 38.2387 0.00
0.00
Sub Total 5176.77 -3815.88
Total 1360.89

Time Temperat
Capacity
Load Change in Duration of to End ure Positive Negative
Period Rating
(A) Load Period Sectio Derating Values Values
Factor, Kt
n Factor
Section 4-First 4 Periods Only – if A5 is greater than A4, go
YES
to Section 5 - YES
A1=78 7863.754
1 A1-0=789.28 1 599.00 9.580 1.04 0.00
9.28 5
A2=20 A2-A1= -
2 179.00 598.00 9.560 1.04 0.00 -5846.13
1.28 588.00
A3=21
3 A3-A2=9.6 180.00 419.00 7.180 1.04 71.685 0.00
0.88
A4=20
4 A4-A3=-9.6 239.00 239.00 4.620 1.04 00 -46.1261
1.28
Sub Total 7935.44 -5892.26
Total N/A 2043.18

Time Temperat
Capacity
Load Change in Duration of to End ure Positive Negative
Period Rating
(A) Load Period Sectio Derating Values Values
Factor, Kt
n Factor
Section 5-First 5 Periods Only – if A6 is greater than A5, go
YES
to Section 6 - YES
A1=78
1 A1-0=789.28 1 600.00 10.050 1.040 8249.555 0.00
9.28
A2=20 A2-A1= -
2 179.00 599.00 10.030 1.040 0.00 -6133.55
1.28 588.00
A3=21
3 A3-A2=9.6 180.00 420.00 7.190 1.040 71.785 0.00
0.88
A4=20
4 A4-A3=-9.6 239.00 240.00 4.630 1.040 0.00 -46.23
1.28

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 26 OF 27

TRANSMISSION ENGINEERING STANDARD TES-P-103.02, Rev.01

A5=24
5 A5-A4=40.08 1.00 1.00 1.090 1.100 48.156 0.00
2.08
Sub Total 8369.5 -6202.7
Total 2166.8

Selection of Battery Size:

Uncorrected Battery size (max Fs) = 2166.8 Ah

Design Margin Kd = 1.1
Aging Factor Ka = 1.25

Using equation 7, as per above clause 4.6.2 of Standards:

F  (max FS)Kd Ka (7)

Required Capacity = (max Fs) x Kd x Ka = 2166.8 x1.1x1.25

= 2979.36 Ah (Nearest highest Capacity Ex. 3000 Ah)

Nickel Cadmium Battery shall be selected as per the available Battery Manufacturers
catalog’s nearest highest capacity rating.

8.0 CONCLUSION

88.1 As per above calculation the minimum battery size for 132kV, 115 kV or 110 kV
substation with scope as described in section 3 for Lead Acid Battery is 2950 Ah and
for Nickel Cadmium 3000 Ah 10 hours duration basis.

88.2 The presented calculations shall be used as a guideline only. The contractor/designer
shall however, compute the required battery size for each project based on above
respective guidelines. The appropriate size of the battery to be supplied shall be
verified as per actual load requirements.

TESP10302R01/RBA Date of Approval: March 17, 2020 PAGE 27 OF 27