110V Battery & Battery Charger Sizing Calculation for

Sherpur (Bogra)

 Project Name: Design, supply, installation, testing & commissioning

of 132/33kv sub-stations at Sherpur (Bogra) & Kurigram,Capacity
upgradation of existing 132/33kv sub-stations at Thakurgaon ,Palashbari,
Sirajganj, Natore &amp ; Chapainawabganj and 132kv bay extension at
Rangpur sub-station.

 Contract No.: PGCB/WB/ECGSTL/SS/W02; Dated: 28-07- 2016.

 Contractor: Consortium of ENERGYPAC-DAEWOO

 Client: POWER GRID COMPANY of BANGLADESH

 CONTENTS

Page No.

1 INTRODUCTION 3

2 DESIGN CRITERIA FOR BATTERY SIZING 3

3 CALCULATION FOR NUMBER OF CELLS 4

4 DESIGN CRITERIA FOR BATTERY CHARGER SIZING 5

5 REFERENCES 5

6 ASSUMPTIONS 5

7 CALCULATION 6-13

i 110V DC LOAD DETAILS 6-7

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

8 RESULT 5

9 ANNEXURES:-

i DVR Calculation

ii UPS Sizing

iii K- factor curves (HBL)

iv Temperature correction factor (HBL)

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

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

battery charger required for 132/33kV Substation at Sherpur (BOGRA).
The battery is sized in accordance with the IEEE 1115-2000 .
110V DC Power supply will consist of two number 100% rated battery along
with two number of 100% rated dual float cum boost charger to charge above
batteries.

2 DESIGN CRITERIA FOR BATTERY SIZING:

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

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

the battery.

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

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

iv Battery can supply load at discharge rate of 5 hours without terminal voltage
drop from rated voltage.

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

Accordingly, the load cycle is divided into six sections:

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

Section Number Time Period Load Considered

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

The minimum temperature is 4 °C

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

Page-3
3 CALCULATION FOR NUMBER OF CELLS

Nominal Voltage of the system = 110 V

Maximum Allowable system voltage percentage = +10 %

Maximum allowable system voltage = 121 V

Minimum allowable system voltage = -20 %

Minimum allowable system voltage = 88 V

End cell voltage = 1.0 V

Float charging voltage = 1.40 V

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

= 121 / 1.40
= 86.4

Minimum No. of cells required = 87.00

No. of cells selected = 92.00

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

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

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

Page-4
4 DESIGN CRITERIA FOR BATTERY CHARGER SIZING

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

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

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

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

6 ASSUMPTIONS

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

ii Total Emergency lighting load is considered 600 W.

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

7 CALCULATIONS

i 110V DC Load details

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

8 RESULTS
i 110V Battery Size Selected 461 AH
ii Charger Selected 120 A

Page-5
Maximum section size = 262.6 AH

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

factor x Aging factor

Battery size calculated = 332.189 AH

Nearest standard rating = 346 AH

Battery size selected = 461 AH

Standing DC loading for Protection, Control, Indications and alarms = (132kV line feeder control
and relay panel load + transformer feeder control and relay panel load + Bus coupler feeder
control and relay panel load + 33kV Incomer panel load + DC/DC converter load)

= (864 + 450 + 145 + 122 + 1000) Watts [ values were taken from Table 1]

= 2581 Watts

= 23.46 Amp.

Battery size selected = 461 AH

Battery can backup the above mentioned load upto (461 / 23.46) = 19.65 Hours

Which Fulfills PGCB’s requirement.

Page-11
FLOAT CUM BOOST CHARGER SIZING CALCULATION
SELECTED BATTERY SIZE
DC Nominal Voltage
A) FLOAT CHARGER RATING
Float Charger Rating
Continuous Load Current
Float Charging Current
Float Charger Rating Calculated
Design Margin
Rating of Battery Charger
B) BOOST CHARGER RATING
Boost Charger Rating
Boost Charger Rating Calculated
Design Margin
Rating of Battery Charger
Battery Charger Rating Selected
RESULT
No. of Battery Cells
AH Capacity
Float cum Boost Charger rating
= 461 AH
= 110 V
= (Continuous load current + Float charging current)
= 42.55 A
= 2 mA per AH rating of battery
= 0.922 A
= 43.47 A
= 10%
= 47.81 A
= 20% of AH Rating of battery
= 92.2 A
= 10%
= 101.42 A
= 120 A
= 92 Nos.
= 461 AH.
= 120A at 110V DC
Page-12
 HBL Power Systems Ltd

K - Factors Curve for L type Cells

1 to 8 Hours duration

8
K - FACTOR (Ah/A)

6
ECV

1.14 V
5 1.1 V

1.05 V

1.0 V
4

1
1 2 3 4 5 6 7 8
DURATION (Hours)
 HBL Power Systems
Ltd
K - Factors Curve for L type Cells
1 to 60 Minutes duration

1.85

1.65
 HBL Power Systems Ltd
1.45
ECV
K - Factors Curve for L type Cells 1.14 V

1.25 1.1 V

1.05 V

1.0 V
1.05

0.85

0.65
K - FACTOR (Ah/A)

0.45
0 10 20 30 40 50 60
DURATION (Minutes)
 1 to 60 Seconds duration
0.85

0.8

0.75
 0.7
ECV
1.14 V
0.65
1.1 V

1.05 V
0.6
1.0 V

0.55

0.5

0.45
K - FACTOR (Ah/A)

0.4
0 10 20 30 40 50 60
DURATION (Seconds)
 HBL NIFE Power Systems Ltd

NICKEL CADMIUM BATTERY - TEMPERATURE DERATING FACTORS

(TO BE APPLIED TO THE PERFORMANCE AS GIVE IN TECHNICAL DATA BROCHURE)
ELECTROLYTE CELL 1 30 1 2 5 10 30 1 1.5 2 3 4 5 6 7 8 9 10
TEMP TYPE Sec Sec Min Min Min Min Min Hr Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs Hrs

L 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.96 0.97 0.98 0.99 0.995 0.995 1.00 1.00 1.00 1.00 1.00
15°C.
M 0.94 0.95 0.95 0.95 0.95 0.95 0.97 0.98 0.985 0.99 0.995 1.00 1.00 1.00 1.00 1.00 1.00 1.00

H 0.94 0.95 0.95 0.95 0.95 0.96 0.98 0.99 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

L 0.88 0.89 0.89 0.895 0.895 0.9 0.91 0.925 0.94 0.95 0.96 0.97 0.97 0.975 0.975 0.975 0.975 0.975
10°C.
M 0.85 0.86 0.87 0.875 0.88 0.9 0.92 0.95 0.955 0.96 0.97 0.98 0.98 0.98 0.98 0.98 0.98 0.98

H 0.87 0.88 0.88 0.89 0.9 0.91 0.94 0.95 0.96 0.97 0.98 0.98 0.99 0.99 0.99 0.99 0.99 0.99

L 0.75 0.765 0.77 0.77 0.77 0.77 0.79 0.81 0.83 0.85 0.87 0.88 0.89 0.9 0.9 0.9 0.9 0.9
0°C.
M 0.75 0.75 0.75 0.76 0.76 0.78 0.82 0.85 0.87 0.88 0.9 0.91 0.92 0.94 0.95 0.95 0.95 0.95

H 0.76 0.77 0.77 0.78 0.78 0.79 0.83 0.88 0.9 0.92 0.94 0.95 0.95 0.96 0.96 0.97 0.97 0.97

L 0.63 0.63 0.63 0.63 0.63 0.64 0.65 0.675 0.7 0.725 0.76 0.78 0.79 0.8 0.8 0.8 0.81 0.82
-10°C.
M 0.63 0.63 0.63 0.63 0.64 0.65 0.68 0.72 0.75 0.78 0.81 0.84 0.85 0.86 0.87 0.87 0.87 0.87

H 0.6 0.63 0.64 0.64 0.65 0.66 0.71 0.77 0.8 0.83 0.85 0.87 0.88 0.89 0.9 0.9 0.9 0.91

L 0.5 0.5 0.5 0.5 0.5 0.51 0.54 0.56 0.58 0.61 0.65 0.68 0.69 0.7 0.71 0.72 0.73 0.74
-18°C.
M 0.5 0.5 0.51 0.51 0.52 0.54 0.57 0.61 0.65 0.68 0.73 0.75 0.77 0.78 0.8 0.8 0.8 0.8

H 0.5 0.52 0.53 0.54 0.55 0.56 0.61 0.67 0.71 0.75 0.78 0.81 0.83 0.84 0.85 0.85 0.85 0.86

Note: For intermediate temperature and time period the temperature derating factors can be calculated by interpretation method.