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Table of contents
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0

Intent
Reference documents/ drawings
Codes and standards
System data
System description
Design criteria
Calculation
Conclusion
Annexure-1 as attachment at the end of the document (8 sheets)

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Sizing Calculation
1.0 Intent
Intent for this document is to calculate the size of 220V DC unit 1/ 2 and station service, lead acid plante
batteries and associated float cum boost chargers (FCBC).
Sizing calculation for 400kV switchyard 220V DC battery and associated float cum boost chargers (FCBC) is
being submitted as a separate document (ABB doc no.- 3VYN591603-A).
2.0 Reference documents/ drawings
a. DBR Electrical system:
b. Key SLD:
c. DC load list:

ABB document 3VYN931101-A, Rev 2

ABB drawing 3VYN931101, Rev 2
As provided by CVL email dated February 11, 2010

3.0 Codes and standards

IEEE Std. 485
IS 1651
IS 1652

IEEE recommended practice for sizing lead-acid batteries

for stationary applications
Stationary cells and batteries, lead-acid type (with tubular
positive plates) - specification
Stationary cells and batteries, lead-acid type (with plante
positive plates) - specification

4.0 System data

a. Nominal DC system voltage:
b. Permissible variations in DC supply:
c. DC system fault level:
d. DC system earthing:
e. Design ambient temperature:
f. Site ambient conditions:
1. Maximum temperature:
2. Minimum temperature:

220V
-15% to +10% (187V to 242V)
25kA at DCDB level
Un-earthed
50C
48.3C
5C

5.0 System description

The proposed power project involves two identical turbine generator units of 150MW size each. For each unit,
a dedicated 220V DC system with 1x100% lead-acid plante battery and 2x100% FCBC (float cum boost
charger) with one number DCDB (DC distribution board) is envisaged.
To cater DC requirements of station service a dedicated 220V DC system with 1x100% lead-acid plante battery and 2x100% FCBC (float cum boost charger) with one number DCDB (DC distribution board) is considered.
Unit and station batteries shall have equal AH capacity and sized so, that in case of failure of one of the battery sets, nearby battery can take care of affected DC loads.
Interconnection of station 220V DC system to unit (1 & 2) 220V DC systems shall be provided at DCDB level.
Each unit 220V DC battery bank shall feed to following loads:
a. BTG (boiler-turbine-generator) DC requirements as provided/ confirmed by CVL
b. GCB (generator circuit breaker) control and protection DC requirements
c. GT/ UAT/ UST DC requirements
We reserve all rights in this document and in the information therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
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6.6kV MV unit auxiliary switchgear control and protection DC requirements

415V LV unit PMCC control and protection DC requirements
415V LV Boiler MCC control and protection DC requirements
415V LV ESP PMCC control and protection DC requirements
Emergency MCC control and protection DC requirements
6.6/0.433VkV station service distribution transformer marshalling box control supply
Unit DC lighting
Station DC requirement

Station 220V DC battery bank shall feed to following loads:

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.

6.6kV MV unit station service switchboard control and protection DC requirements

415V LV station service PMCC control and protection DC requirements
415V LV AHP PMCC control and protection DC requirements
415V LV WTP PMCC control and protection DC requirements
415V LV FHS PMCC control and protection DC requirements
415V LV ACC PMCC control and protection DC requirements
6.6/0.433VkV station service distribution transformer marshalling box control supply
DG board (not under ABB scope of supply) control and protection DC requirements
Station DC lighting
DC load of one unit (1 or 2)

6.0 Design criteria

220V DC lead-acid plante battery
1. The ampere-hour (AH) capacity of the DC storage battery is based on one hour supply to the essential auxiliaries.
2. Battery shall be rated for 10 hour discharge rate (C10) as per manufacturer data.
3. The battery is sized such that the voltage at any time during duty cycle will not be less than1.85V per
cell.
4. Method of computing the battery capacity from duty cycle is as per IEEE Std. 485.
5. K-factor as required in IEEE Std. 485 cell sizing worksheet is taken from manufacturer (Exide) software program.
6. Following factors shall be considered for battery sizing:
a. Temperature correction factor =

7.

8.
9.
10.
11.

, where

R= 0.9 for 10hrs discharge per table-2 of IS 1652

t = minimum site temperature plus incremental temperature of 10C
b. Design margin = 10%
c. Aging factor = 1.0 (for plante type lead-acid battery)
The AH (ampere hour) capacity of the battery is calculated for:
a. Momentary loads: 0 to 1/ 1 to 5 / & 5 to 6 minutes
b. Continuous control and annunciation loads: 6-59 minutes
c. Impulse loads: 59 to 60 minute
Tripping of circuit breaker load is considered as 1st minute load of duty cycle.
Control supply to switchyard relay/ control panels are considered for the entire load of 1 hour.
Closing of circuit breaker load is considered at last minute of duty cycle.
Start of jacking oil pump is considered at the 5th minute of duty cycle.

Battery charger
1. Battery charger will have a minimum rating to meet the following loads:
a. Normal DC load plus trickle charge current of the battery.
b. Boost/ equalizing charging current of the battery at high rate.
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2. The maximum design recharge time shall be not greater than 10 hours for lead acid battery
while simultaneously supplying power to the DC loads through float charger.
3. The charger rating shall provide a 25% margin over the estimated DC system load.
7.0 Calculation
220V DC lead-acid plante battery for unit -1/ 2 and station service
Inputs:
1. Type of battery:
Lead acid plante
2. Manufacturer:
Any approved
3. Nominal DC system voltage:
220V
4. Maximum DC system voltage:
+10% (i.e. 242V)
5. Minimum DC system voltage:
-15% (i.e. 187V)
6. End cell voltage (ECV):
1.85V/ cell
7. Float voltage:
2.25V/ cell
8. Electrolyte temperature:
(5+10) = 15C
9. Temperature correction factor:
10. Design margin:
11. Ageing factor:
12. Number of duty cycle:

= 1.108
10%
1.0 (for plante type lead-acid battery)
Five (5)

Determination of number of cells:

Number of cells required

Calculated minimum system voltage

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107.5

110

(ECV * Number of cells selected)

1.85 * 110 = 203.5V, i.e.

Calculated minimum system voltage is greater than the allowable minimum system voltage. Thus, the
determination of number of cells as 110 is justified.
AH (ampere-hour) capacity calculation for battery is carried out per IEEE Std. 485 and is attached as
Annexure-1 at the end of this document.
Selected battery rating = 1043.86AH

1070AH

Battery charger
Float charger current rating = (continuous DC requirement + float charging requirement for battery)
Where,

Continuous DC requirement = 170.08A (refer Annexure-1)

Float charging requirement for battery (1.5mA per AH) = (1070*0.0015) = 1.605A, thus
Float charger current rating = (170.08+1.605) = 171.685A

With 25% design margin, Float charger current rating = (171.685*1.25) = 214.60A
During plant normal operation, turbine emergency oil pump (EOP) may be required to run for testing
purposes, considering this fact;
Float charger current rating = (214.60+EOP (11kW) nominal FLA) = (214.60+50) = 264.6A
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Boost charger current rating = (float charger rating) or (15% of battery AH + 25% design margin)
whichever is higher
Float charger current rating =
15% of battery AH + 25% design margin =

264.6A
(1070*0.15) * 1.25 = 200.625A

Boost charger current rating = 264.6A

Selected rating of float cum boost charger = 275A
8.0 Conclusion
Selected 220V DC storage battery capacity for unit -1 & 2 and station service = 1x100%, 1070AH each
Selected FCBC charger capacity for unit -1 & 2 and station service = 2x100%, 275A each
******

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