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SHEET i OF i
30421007-3CL00016-P0A
DESIGN BASIS
FOR
125V DC STATION BATTERY & BATTERY CHARGER SIZING
DOCUMENT NO : 30421007-3CL-00016-P0A
OCTOBER 2004
ENGINEERING CONSULTANT
TCE CONSULTING ENGINEERS LIMITED
73/1, ST.MARK'S ROAD
BANGALORE 560001
INDIA
CONTRACTOR:
AL-TOUKHI COMPANY FOR INDUSTRY & TRADING
P.O.BOX 497, RIYADH 11411, KINGDOM OF SAUDI ARABIA
TEL.00966-1-14633660 : FAX.00966-1-4631150
P0A
26.10.2004
MP
SR
PREPARED BY
CHECKED BY
278172441.xls
SECTION :cover sheeet
CLEARED BY
APPROVED BY
SHEET 1 OF 22
278172441.xls
SECTION :cover sheeet
PREPARED BY
CHECKED BY
CLEARED BY
APPROVED BY
SHEET 2 OF 22
CALCULATION DOCUMENT
CONTENTS
SECTION
DESCRIPTION
1.0
PURPOSE
2.0
3.0
SIZING CRITERIA
4.0
5.0
CONSIDERATIONS
6.0
7.0
8.0
9.0
10.0
DC LOAD ESTIMATION
11.0
CONCLUSION
278172441.xls
SECTION :Index
SHEET 3 OF 22
278172441.xls
SECTION :Index
SHEET 4 OF 22
1.0 PURPOSE:
The purpose of this calculation is to determine the sizes of the 125V DC battery and battery charger for
the Station DC System of GTG#7 and GTG#8 of ARAR Central Power Station.
2.0 STANDARDS & REFERENCES
2.1
SCECO Engineering Standard SES-P-103.02 - Revision 3 Storage Battery Selection and Capacity
determination
2.2
2.3
IEEE-485 - IEEE Recommended Practice for Sizing of Large Lead Acid Storage Batteries for Generating
stations and Sub Stations.
2.4
Key One Line Diagram for Arar Plant Drawing No:KA-667481, Rev-P0D SHEET 1 OF 1
The battery has been sized to meet the Station DC loads, namely the switchgear control supplies and the
Lighting load in the event of black out, for a period twelve (12) hours.The DC Loads pertaining to Gas
turbine and Generator Auxiliaries are not considered as part of these calculation.since these loads would
be catered to unit DC system.
3.2
The Type of battery selected is Vented Type Lead Acid Battery as per cl no 3.03-19(a), page 40 of 336 of
PTS-1022
3.3
The tripping/closing coil/spring charging motor loads for MV breakers are based on Schneider Electric
switchgear catalogues.
3.4
3.5
Design marigin factor of 1.1 has been considered as per cl.no.4.4.2 of SES-P-103.02
3.6
Ageing factor of 1.25 has been considered as per cl.no. 4.4.3 of SES-P-103.02
3.7
The Battery room temperature is considered as 25 deg C and the temperature correction factor of 1.19
based on inside room temperature of 10 Deg C in case of power failure is considered as per cl.no 2.2 of
SES-P-103.02. Page 17 of 35
3.8
Capacity correction factors and Temperature correction factors are based on SCECO engineering
standard SES-P-103.02.
278172441.xls
SECTION :Writeup
SHEET 5 OF 22
4.0.2
On return of normal power supply, simutaneous closing of one incomer & one outgoing feeder, tripping
of one breaker if fault persists, starting of one spring charging motor and running of one spring charging
motor are considered as per c.l.no.2.3(b) of SES-P-103.02. page no 18 of 35. This load is considered
as 1 minute load prior to end of duty cycle.
4.0.3
Starting current of spring charging motor is taken as 5 times the normal current as per cl.no 2.4 SES-P103.02.
4.0.4
4.0.5
DC Emergency lighting load for 3 hours which will be switched on within 3 hours of power failure in
accordance with cl.no. 2.6 of SES-P-103.03
5.0
5.1.1
CONSIDERATIONS
Maximum of 2000Watts of lighting loads has been considered.
5.1.2
The following type of indication lamps and transducers have been condsidered for the MV breakers
(a) Indication Lamps for
(b) Transducers for
i) Breaker -ON
i) Voltage(V) Transducer
ii) R phase -ON
ii) Ammeter(A) Transducer
iii)Y phase -ON
iii) Watt (W) Transducer
iv) B phase -ON
iv) Power Factor(PF) Transducer
v) Trip circuit healthy -ON
v) VAR Transducer
5.1.3
The following type of Indication Lamps & Annunciation have been condsidered for Remote control/
annunciation Panel.
(a) Indication Lamps for
(b) Annunciations for
i) Breaker -ON
i) Transformer Winding Temperature high
ii) R phase -ON
ii) Transformer Winding Temperature very high.
iii)Y phase -ON
iii)Transformer oil temperarue high
iv) B phase -ON
iv) Transformer oil temperature very high
v) Trip circuit healthy -ON
v) Buchholz relay for transformer and OLTC
vi) Pressure relief valve
vii) DC supply supervision relay
viii) Trip circuit supervision relay
ix) O/C & E/F protection
x) REF protection
xi) Differntial protection
xii) Overall Differntial protection
xiii) Lockout relay
xiv) Under Voltage Relay
xv) AC trip coil healthy
278172441.xls
SECTION :Notes for Sizing
SHEET 6 OF 22
278172441.xls
SECTION :Notes for Sizing
SHEET 7 OF 22
6.0
DOCUMENT NO.30421007-3CL-00016-P0A
2 volts
125 volts
Float voltage
2.2 volts
1.75 volts
101.5 volts
136.3 volts
Number of cells required considering the minimum system voltage and end cell voltage =
101.5/1.75
58.00
..(i)
Number of cells required considering the maximum system voltage and float voltage =
136.3/2.2
61.95
..(ii)
58.00
Maximum system voltage considering 58cells and float voltage of 2.2 volts is 58 * 2.2
=
<
127.6
136.3
volts
volts
Hence the maximum voltage developed during float charging is less than the maximum permissible
system voltage.
Hence, selection of 58 cells is justified.
7.0
278172441.xls
SECTION :Cell Number
SHEET 8 OF 22
DOCUMENT NO30421007-3CL-00016-P0A
D U TY CYC LE ( D C LOAD PR O F I LE )
L
O
A
D
A5=134
I
N
A1=42
A
M
P
S
A5
A3=41
A1
A2=25
A4=25
A4
A3
A2
0
180
360
719
720
MINUTES
SKETCH (Not to Scale)
NOTE:
Refer CL.No: 10.0: DC Load Estimation for calculation of load currents A1 to A5
278172441.xls
SECTION :DUTY CYCLE
SHEET 9 OF 22
278172441.xls
SECTION :DUTY CYCLE
SHEET 10 OF 22
CALCULATION DOCUMENT
9.0
Period
Load
3
Change in Load
Duration Of
Period
25A
134A
7
Capacity
Temperatur
Factor at t
e Derating
Min. rate ( KT) Factor for t
Min.( Tt)
A3=
41A
8
Reqd. Section Size)
Pos. Values
Section 1: First Period Only - if A2 is greater than A1, go to Section 2
1 A1=
A1=42
A1-0=42
M1=1
t=M1=1
0.7700
Section 1
1.19
Total
Neg. Values
38.48
38.48 AH
A1=42
A1-0=42
M1= 1
t= M1 + M2 =180
3.7000
1.19
2 A2=
A2=25
A2-A1= - 17
M2 = 179
t= M2 = 179
3.6800
1.19
Section 2
Sub. Total
Total
184.93
-74.45
184.93
-74.45
110.48 AH
A1=42
A1-0=42
M1 = 1
t= M1 + M2 + M3 = 360
6.2900
1.19
2 A2=
A2=25
A2-A1= -17
M2=179
t=M2 + M3 = 359
6.2700
1.19
3 A3=
A3=41
A3-A2= 16
M3=180
t = M3 = 180
3.7000
1.19
Section 3
278172441.xls
SECTION :Battery&ChargerSizing
314.37
-126.84
70.45
Sub. Total
384.82
Total
257.98 AH
-126.84
SHEET 11 OF 22
CALCULATION DOCUMENT
Section 4 : First Four Periods Only - if A5 is greater than A4, go to Section 5
1 A1=
A1=42
A1-0=42
M1 = 1
t= M1 + M2 + M3+M4 = 719
10.7400
1.19
2 A2=
A2=25
A2-A1= -17
M2=179
10.7200
1.19
3 A3=
A3=41
A3-A2= 16
M3=180
t = M3+M4 = 539
7.7100
1.19
4 A4=
A4=25
A4-A3= -16
M4=359
t = M4 = 359
6.2700
1.19
Section 4
536.79
-216.87
146.80
-119.38
Sub. Total
683.58
Total
347.34 AH
-336.25
A1=42
A1-0=42
M1 = 1
t= M1 + M2 + M3 + M4+M5=
720
10.7600
1.19
2 A2=
A2=25
A2-A1= -17
M2=179
t= M2 + M3 + M4+M5= 719
10.7400
1.19
3 A3=
A3=41
A3-A2= 16
M3=180
t= M3 + M4+M5= 540
7.7300
1.19
3 A4=
A4=25
A4-A3= -16
M4=359
t= M4+M5= 360
6.2900
1.19
3 A5=
A5=134
A5-A4= 109
M5=1
t = M5 = 1
0.7700
1.19
Section 5
Uncorrected Cell Size = Maximum Section Size
Design Margin =
Aging Factor =
Cell Size =
278172441.xls
SECTION :Battery&ChargerSizing
537.78
-217.27
147.18
-119.76
122.78
Sub. Total
807.75
Total
470.72
10%
1.25
470.72 AH
647.24
650
-337.03
AH
AH
SHEET 12 OF 22
CALCULATION DOCUMENT
SF X L +
RT
Where,
SF
= Service Factor
1.1
= continuous DC load
27
BIF
1.1
AHR =
470.72
AH
RT
Recharging time
16
Hrs
278172441.xls
SECTION :Battery&ChargerSizing
62.06
Amps
68.27
Amps
70
Amps
SHEET 13 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
A.
1
4.16kV Switchgear
Indication lamps
1.2
35
42
42
42
42
42
42
Protective Relays
50
350
350
350
350
350
350
Auxiliary relays
3.3
35
115.5
115.5
115.5
115.5
115.5
115.5
Transducers
1.5
35
52.5
52.5
52.5
52.5
52.5
52.5
5
6
Multifunction Meter
Tripping coil
C
M
6
50
7
16
42
800
42
0
42
0
42
0
42
100
42
0
Closing coil
50
200
300
3000
300
600
1402.00
602.00
602.00
602.00
4502.00
602.00
1.2
65
78
78
78
78
78
78
Protective Relays
50
13
650
650
650
650
650
650
278172441.xls
SECTION :DC LOAD ESTIMATION
SHEET 14 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
5 nos Auxiliary Relays are
considered for each breaker
Transducers are considered for VX,
AX, WX, PFX,VARX
Auxiliary relays
1.3
65
84.5
84.5
84.5
84.5
84.5
84.5
Transducers
1.5
65
97.5
97.5
97.5
97.5
97.5
97.5
5
6
Multifunction Meter
Tripping coil
C
M
6
50
13
12
78
600
78
0
78
0
78
0
78
100
78
0
Closing coil
50
200
300
3000
300
600
1588
988
988
988
4888
988
1.2
15
18
18
18
18
18
18
Protective Relays
50
150
150
150
150
150
150
Auxiliary relays
1.3
15
19.5
19.5
19.5
19.5
19.5
19.5
Transducers
1.5
15
22.5
22.5
22.5
22.5
22.5
22.5
5
6
Multifunction Meter
Tripping coil
C
M
6
50
3
4
18
200
18
0
18
0
18
0
18
50
18
0
278172441.xls
SECTION :DC LOAD ESTIMATION
SHEET 15 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
Closing coil
50
100
300
1500
300
300
428
228
228
228
2178
228
1.2
15
18
18
18
18
18
18
Protective Relays
50
150
150
150
150
150
150
Auxiliary relays
1.3
15
19.5
19.5
19.5
19.5
19.5
19.5
Transducers
1.5
15
22.5
22.5
22.5
22.5
22.5
22.5
5
6
Multifunction Meter
Tripping coil
C
M
6
50
3
4
18
200
18
0
18
0
18
0
18
50
18
0
Closing coil
50
100
300
1500
300
300
428
228
228
228
2178
228
278172441.xls
SECTION :DC LOAD ESTIMATION
SHEET 16 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
Indication lamps
1.2
15
18
18
18
18
18
18
Protective Relays
50
150
150
150
150
150
150
Auxiliary relays
1.3
15
19.5
19.5
19.5
19.5
19.5
19.5
Transducers
1.5
15
22.5
22.5
22.5
22.5
22.5
22.5
5
6
Multifunction Meter
Tripping coil
C
M
6
50
3
4
18
200
18
0
18
0
18
0
18
50
18
0
Closing coil
50
100
278172441.xls
SECTION :DC LOAD ESTIMATION
SHEET 17 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
300
1500
300
300
428
228
228
228
2178
228
70
70
70
70
70
70
70
50
50
120
0
70
0
70
0
70
0
70
0
70
70
70
70
70
70
70
70
50
50
120
0
70
0
70
0
70
0
70
0
70
70
70
70
70
70
70
70
50
50
120
0
70
0
70
0
70
0
70
0
70
60
60
60
60
60
60
60
60
60
60
60
60
60
G.
1
H.
1
278172441.xls
SECTION :DC LOAD ESTIMATION
SHEET 18 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
J.
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
60
60
60
278172441.xls
SECTION :DC LOAD ESTIMATION
60
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
60
SHEET 19 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
Remote Control
1.2
15
18
18
18
18
18
18
Annunciation
1.2
48
57.6
57.6
57.6
57.6
57.6
57.6
75.6
75.6
75.6
75.6
75.6
75.6
1.2
15
18
18
18
18
18
18
Annunciation
1.2
48
57.6
57.6
57.6
57.6
57.6
57.6
75.6
75.6
75.6
75.6
75.6
75.6
1.2
15
18
18
18
18
18
18
Annunciation
1.2
48
57.6
57.6
57.6
57.6
57.6
57.6
75.6
75.6
75.6
75.6
75.6
75.6
278172441.xls
SECTION :DC LOAD ESTIMATION
SHEET 20 OF 22
CALCULATION DOCUMENT
10.0 DC LOAD ESTIMATION
SL.
No.
Load Description
DOCUMENT NO30421007-3CL-00016-P0A
A1
A2
Type Unit
Qty 0-1 minute 1-180 minute
of
Load
load
load
Load (Watts)
(watts)
(watts)
A3
A4
A5
180-360
360-719
719-720
minute load minute load minute
(watts)
(watts)
load(watts)
Continuous Remarks
Load on
Charger
(watts)
1.2
15
18
18
18
18
18
18
Annunciation
1.2
48
57.6
57.6
57.6
57.6
57.6
57.6
75.6
75.6
75.6
75.6
75.6
75.6
1.2
15
18
18
18
18
18
18
Annunciation
1.2
48
57.6
57.6
57.6
57.6
57.6
57.6
75.6
75.6
75.6
75.6
75.6
75.6
0
0.00
0
0.00
2000.00
2000.00
0.00
0.00
0
0
0.00
0.00
5312.00
3162.00
5162.00
3162.00
16812.00
3162.00
42
25
41
25
134
25
DC Lighting
Sub Total Load : (V) in Watts
278172441.xls
SECTION :DC LOAD ESTIMATION
Lot
SHEET 21 OF 22
11.0 CONCLUSION
(a) Recommended minimum battery size for the station DC system of GTG#7 and GTG # 8 including one
future GTG of ARAR Power station is 650AH on 12 hours duration basis.
(b) A battery charger of 70 Amps rating shall be provided.
278172441.xls
SECTION :Conclusion
SHEET 22 OF 22