CONTENTS

Sr. Description Page No.

1 Scope 3
2 Battery & Battery charger System for Main Control Room 3
3 Calculation
3.1 Calculating number of cells 5
3.2 Summary of loads 5
3.3 Battery Duty cycle & AH Capacity 5
3.4 Battery charger sizing calculation for Float/Boost Charging 6

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 1 SCOPE

This document covers Battery & Battery charger sizing calculation of 125 D.C. systems for Switchgear control for 405 MWp Solar plant at ABG,Odisha

2 BATTERY & BATTERY CHARGER SYSTEM FOR SWITCHGEAR CONTROL

I Input voltage / frequency : 400 V + 10 % / 50Hz + 5 %
II Nominal Output voltage : 110 V DC
III Maximum Voltage : 121 V DC
IV Minimum Voltage : 99 V DC
V Individual cell voltage : 2 V DC
VI Battery end cell voltage : 1.85 V DC
VII Float Charging voltage : 2.25 V DC
VIII Type of Batteries : VRLA,SMF
IX Battery Back up time : 8 Hours (480 Minutes)
X Ambient temperature : 50 º C
XI Electrolyte Temperature : 10 º C = 50 º F
XII Ageing factor : 25%
XIII Future provision : 5%
XIV Design Margin : 10%
XV Reference Standard : IEEE 485
XVI Assumtions :
a. Continuous Loads : i) Indicating Lamps (33kV Switchboard)
ii) Protective Relays (33kV Switchboard)
iii) Aux. Contactors / Relays for multiplication of contacts
iv) Other Miscellaneous loads
b. First Minute Loads : i) Trip Coil load
ii) Continuous loads (As mentioned in XVI.a.)
c. Last Minute Loads : i) Closing Coil load
ii) Continuous loads (As mentioned in XVI.a.)
XVII Conclusion :
a. Battery size : 110V, 120AH
b. Battery Charger rating : 110V, 30A

2A. BATTERY AND CHARGER SIZING

2A.1 CALCULATION BASIS
The Duty cycle of the Battery is based on the following D.C loads:
A) Continuous Load :
1) Indicating lamps (33 KV SWBD in MCR)

Following indication lamps/Semaphore shall remain ON / OFF at a time in a worst condition for following type of breaker feeders.

No of Lamps for B/C & No of Lamps for

SWBD/SWGR No of Lamps for I/C Feeders No of Lamps for O/G Feeders Total Qty for Switchgear Panel
BUS PT Feeders BUS PT Feeders
Breaker On 4 1 2 0 7
Breaker Off 4 1 2 0 7
Breaker "Auto Trip" 4 1 2 0 7
Spring Charged 4 1 2 0 7
Service Position 4 1 2 0 7
Test Position 4 1 2 0 7
Earth Switch On 4 0 2 0 6
Earth Switch Off 4 0 2 0 6
AC Supply Fail 4 1 2 0 7
DC Supply Fail 4 1 2 0 7
R Phase Healthy 4 2 2 0 8
B Phase Healthy 4 2 2 1 9
Y Phase Healthy 4 2 2 1 9
EM Push Button 4 1 2 1 8
Total Nos of Lamps 102
Total No of Indicating Lamps = 102
No of Indicating Lamps in ON condition all the time = 396

Total Load of Indicating Lamps = 396 X 1 W/Lamp

= 396.00 W (1)

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 c) Protections for 33KV Switchgear Feeder
Qty. for Bus Coupler Qty. for Bus PT Qty. for Outgoing
Protections Relay Device No. Unit Watt Qty. for Incomer Feeder Qty. for Aux Trafo Feeder Total Watt
Feeder Feeder Feeder
50/50N/51/51
Instantaneous Over current & Earth Fault Relay
N
Undervoltage Relay 27
REF615F 5 3 1 1 0 2 35
Overvoltage Relay 59
Breaker Failure Relay 50BF
Ground Instantaneous Overcurrent 50G
Anti Pumping Relay NL22E 94 5 3 1 1 0 2 35
Trip Circuit Supervision Relay TCS 95 2 3 1 1 0 2 14
Master Trip Relay PQ8n 86 9 3 1 1 0 2 63
Auxiliary Relay-Trafo Fault CR-M 63X 2 0 10 0 0 0 20
Annunciator Windows (8-window) ANNUN - 12 3 0 1 0 0 48
Annunciator Windows (12-window) ANNUN - 18 0 0 0 0 2 36
Annunciator Windows (16-window) ANNUN - 24 0 1 0 0 0 24
251

Number of HT Switchgear = 1 Nos. Total Relay Load of HT Switchgear 251

Total Protective Relays Load = 647.00
= 647.00 W ------------------------------------------ (2)

3) Aux. Contactors / Relays for multiplication of contacts for logic requirements of schemes and Indications purpose

1 No. Aux. Relay / Contactor per feeder and burden of 4 W per Aux. Relay
Load of Auxiliary Relays = 9 X 4 W/ Aux. Relay (9-33KV Fdr )
= 36.00 W ------------------------------------------ (3)

Total Continuous Load = (1) + (2) + (3)

= 1079.00 W
Hence, Load in Amp. = 8.63 Amp
Say, 9.00 Amp ------------------------------------------ (A)

B) First minute load at the beginning of the battery load cycle (0 to 1 min) :

A Typical fault is considered for Battery sizing, which will lead to tripping of 33KV side incomers/outgoing feeders.

The battery has to supply following momentary loads during first minute:

SWBD/SWGR Feeder Type No of Feeders Operation Trip coil burden Total Watt

33 KV Switchgear O/G-1,2 2 Tripping 200 400

Master Trip Relay O/G-1,2 2 Tripping 5 10
Anti Pumping Relay O/G-1,2 2 Tripping 9 18
Aux Trafo Relay O/G-1,2 2 Tripping 2 4
Total Momentary Load during First Minute 432
Hence, Load in Amp. = 3.93 Amp
Say, 4.00 Amp
Adding continuous load = 9.00 Amp
= 13.00 Amp
Say, 13.00 Amp ------------------------------------------ (B)

C) Last minute load at the end of 239 min (239 min to 240 min) :

The battery has to supply following momentary loads during last minute before the AC supply is available to Battery Charger:

SWBD/SWGR Feeder Type No of Feeders Operation Watt per Fdr Total Watt

33 KV Switchgear O/G-1,2 2 Closing 200 400

Anti Pumping Relay O/G-1,2 2 Closing 9 18
33 KV Switchgear O/G-1 1 Tripping 200 200
Total Momentary Load during Last Minute 618

Hence, Load in Amp. = 4.94 Amp

Say, 5.00 Amp
Adding continuous load = 9.00 Amp
= 14.00 Amp
Say, 14.00 Amp ------------------------------------------ (C)

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 The load cycle indicated in clause 2A.2 based on (A) (B) & (C)
2A.2 BATTERY DUTY CYCLE DIAGRAM :
14 Amp
13 Amp
MOMENTARY  +
MOMENTARY CONTINUOUS

A + `CONTINUOUS
9 Amp
m
p
s
CONTINUOUS

0 1 Time in minutes 479 480

Section-I ----------Section-II --------------------------------Section-III-----------------------------------------------------------------Section-III

3 CALCULATION:
3.1 Calculating number of cells (As per IEEE - 485) :
Nominal cell voltage = 2 V
Minimum (End) cell voltage = 1.85 V

3 conditions for calculation of no of cells

= Nominal DC Voltage
a. No of cell = 55 Nos
Nominal cell voltage
= Minumum system DC voltage
b. No of cell = 54 Nos
End cell voltage
Maximum system DC voltage
c. No of cell = = 54 Nos
Float charging voltage
Hence, a battery bank consisting of 55 cells of 2 V per cell is selected.
Electrolyte Temperature = 10 º C = 50 º F

3.2 Summary of loads :

3.2.1 The section wise loads for AH capacity
Period Loads of section Load in Amp.
Section I Momentary Tripping load + Continuous load 13.00
Section II Continuous load 9.00
Section III Momentary Closing load + Continuous load 14.00

3.2.2 Initial cell sizing :

Period Load in Amp. Duration (min) Capacity removed (AH)
Section I 13.00 1.00 0.22
Section II 9.00 238.00 35.7
Section III 14.00 1.00 0.24
Total 36.16

An initial selected cell size (AH) = 36.16

3.3 Battery Duty cycle & AH Capacity

3.3.1 The duty cycle and periods are tabulated as below : (as per IEEE Std 485-1997)

Period Load Time to end Temp. derating

Change in Load (Amp) Duration (min) Capacity factor (kt) Required AH
(Amp) factor
(c) (d) (f) (h=c*f*g)
(a) (b) (e) (Tt) (g)

Section I
1 A1 = 13 A1-0 = 13 M1 = 1 T=M1= 1 0.95 1 12.35
Sub Total Section-I 12.35
Section II
1 A1 = 13 A1-0 = 13 M1 = 1 T=M1+M2= 239 8.68 1 112.84
2 A2 = 9 A2-A1=-4 M2 = 238 T=M2= 238 8.68 1 -34.72
Sub Total Section-II 78.12
Section III
1 A1 = 13 A1-0 = 13 M1 = 1 T=M1+M2+M3= 240 8.68 1 112.84
2 A2 = 9 A2-A1=-4 M2 = 238 T=M2+M3= 239 8.68 1 -34.72
3 A3 = 14 A3-A2=5 M3 = 1 T=M3= 1 0.95 1 4.75
Sub Total Section-III 82.87
3.3.2 From above table 3.3.1, it is noted that the maximum AH capacity required is 82.87 AH of section IV.
Applying various factors :
a) Required AH (max. value) = 82.87 = 82.9 AH
b) Aging factor at 25% = 82.87 X 1.25 = 103.6 AH
c) Future Provision at 5% = 103.59 X 1.05 = 108.8 AH
d) Design Margin 10% = 108.77 X 1.1 = 119.7 AH
Accordingly, the battery size is selected is = 120 AH

3.4 BATTERY CHARGER SIZING CALCULATION FOR FLOAT/BOOST CHARGING

Recommended battery size = 120 AH
DC nominal voltage = 110 V
BATTERY CHARGER SIZING FOR FLOAT CHARGING
Battery charger current rating is the sum of the continuous load current and the float charging current of the battery.
Battery charger current rating = 1.15 x Continuous load current + Battery float charging current
Continuous load current = 9 A
Float charging current = 0.2 mA per AH (value to be confirmed from battery manufacture)
= 0.024 A
Battery charger current rating = 10.380 A
Say, 15.00 A
Battery charger rating considered the float charging requirement is110 V, 15 A.

BATTERY CHARGER SIZING FOR BOOST CHARGING

Boost Charging current = 0.2 x AH of the Battery (value to be confirmed from manufacture)
= 24 A
Battery charger current rating = 30 A
Say, 30.00 A
Battery charger rating considered the Boost charging requirement is 110 V, 30A.

Hence Battery charger rating is 110 V, 30 A.

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