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DESIGN GUIDE
FOR
SIZING
CONTENTS
1.0 PURPOSE
2.0 PROCEDURE
1.0 PURPOSE
The purpose of this document is to lay down the guidelines and design procedure for
performing the battery & charger sizing calculation.
2.0 PROCEDURE
For battery backup time required, the customers design basis shall be referred. In the absence
of any specific customer requirements, the backup time can be considered as 1 hour. The
battery sizing shall be done on the basis of the following loads.
The total continuous load is the summation of the loads mentioned below: -
d) DC Lighting load
The wattage of all the lamps operating on DC shall be added to obtain the total DC lighting
load.
The wattage of all other miscellaneous load operating on DC shall be added to obtain the total
miscellaneous load.
The total 1st minute load is the summation of the following loads:-
a) 1st minute load for HT Switchboards
b) 1st minute load for LT Switchboards
c) 1st minute load for MCCS
The total 1st minute load is the summation of the following loads:-
iii) Total auxiliary load i.e. VA, may include load for relay, for auxiliary
relays, timers etc.
The total 60th minute load is the summation of the following loads:-
The total 60th minute load is the summation of the following loads:-
a) Total VA loads of closing coils of the number of breakers which will close at a time.
b) Total VA load of Spring Charging motors of all the breakers, if DC operated
c) Total continuous load.
Number of breakers which will close at a time will depend on the operating philosophy of the
plant (2 Incomer, 1 Buscoupler, & 2 to 4 Outgoing feeders). The VA load of closing coils of each
individual breaker will be obtained from manufacturers data.
The VA load of spring charging motor of each individual breaker shall be obtained from
manufacturers data.
Nominal DC Voltage = V
Considering 10 % voltage variation minimum DC voltage = 0.9 V
N = Number of Cells.
Therefore,
End Cell Voltage = (Minimum DC Voltage) / (Number of Cells)
= (0.9 V) /( N )
Total 1st minute load current = (Total 1st minute load in VA )/ (Minimum DC Voltage)
Total 60th minute load (in VA) is obtained in clause 3.3 above
Total 60th minute load current
= (Total 60th minute load in VA ) / (Minimum DC Voltage )
= ( Total 60th minute load in VA ) / ( 0.9 V )
From the above-obtained values for load cycle currents, the load cycle curve is drawn.
I (in Amps)
T (in min)
0 1 59 60
a) Performance factor
This factor is considered to estimate the performance of the battery at a discharge rate
other than the nominal rate. The performance factor is defined as the ratio of the amperes
that can be drawn from the battery for t minutes to the rated capacity (AH), for a
particular end cell voltage.
This factor is considered to take care of the variations in performance of the battery at
different temperatures. While high temperature results in higher performance, lower than
nominal temperature (27C) lead to lower performance due to sluggish chemical
activities. The performance factor is divided by the temperature correction factor to obtain
the corrected performance factor.
c) Aging factor
The performance of a battery comes down with the time of usage. The battery reaches
the end of its useful life when it fails to deliver 80% of its rated capacity. In order to
deliver its rated capacity even at the end of the estimated life of the battery, a correction
factor of 1.25 ( = 1 / 0.8 ) is taken as aging factor. However, customers design basis shall
also be referred for any specific requirements regarding aging factor.
A spare capacity factor shall be considered to take care of any future additional load.
Customers design basis shall be referred for any customer requirements regarding spare
capacity. In the absence of any specific customer requirements, a spare capacity factor of
1.2 ( 20% additional capacity ) can be considered.
vi) The performance factor is divided by the temperature correction factor to obtain the
corrected performance factor
Corrected performance factor
= (Performance factor ) / (Temperature correction factor )
Here in our case, the corrected performance factor = 1.46 / 1.11 = 1.31
ix) Ampere Hour Capacity Drained shall be calculated from the formula mentioned below: -
AH capacity drained = (Load Current ) * (Time Duration in mins) / ( 60 )
x) AH Balance = AH Required - AH Drained
xi) AH to be added = AH Required - AH Opening Balance.
For the 1st minute, AH Opening Balance = 0
Therefore AH to be added = AH Required
3.5.2 Calculation of Ampere Hour Requirement from the first minute to the 60th minute
ii) AH Opening Balance = AH balance at the end of 1st minute obtained from calculation
in clause 3.5.1 x) above.
i) The value of end cell voltage is the same as obtained in clause 3.5.1 above.
iii) For the value of end cell voltage, the performance factor corresponding to the value of
load current, shall be obtained from manufacturers data. For the determination of
performance factor, even through the actual time duration is 58 min, the time duration
shall be considered as 60 min.
From the attached manufacturers data, for an end cell voltage of 1.14 Volts
per cell, corresponding to load current of 129A for 60 min,
Performance factor = 129 / 285 = 0.45
iv) The value of temperature correction factor is obtained in clause 3.5.1 x) above.
v) The performance factor is divided by the temperature correction factor to obtain the
corrected performance factor.
In this case, corrected performance factor = 0.45 / 1.11 = 0.4
vi) AH Capacity required shall be calculated from the formula mentioned in clause 3.5.1
viii) above.
vii) AH capacity drained shall be calculated from formula mentioned in clause 3.5.1 ix)
above.
iii) The value of end cell voltage is same as obtained in clause 3.5.1 above.
iv) The value of current drawn from the battery during this period is obtained in clause 3.4.3
above.
v) The value of performance factor shall be obtained by the method shown in clause 3.5.2
v) above.
vi) The value of temperature correction factor is already obtained in clause 3.5.1 v) above.
vii) The value of corrected performance factor is obtained by the method shown in clause
3.5.2vii) above.
ix) AH capacity drained shall be calculated from formula mentioned in clause 3.5.1 ix)
above.
The nearest battery AH capacity as per manufacturers rating shall be selected. For example,
if the calculated value of AH Capacity is 645 AH & the nearest rating as per manufacturer is
690 AH, then 690 AH shall be selected.
The customers design basis shall be referred for any customer requirements regarding battery
charger sizing. In the absence of any specific customer requirements, the method mentioned
below shall be followed: -
Battery Float Charger Current Rating = 1.15 * Average DC load + float charge current
Average DC load
= ( Area under the battery duty cycle curve ) / ( Battery duty cycle duration )
The value of float charge factor shall be obtained from battery charger
manufacturer. However, for preliminary battery charger sizing calculation it can be assumed
as 0.01 ( 1 % max.) battery AH capacity. However, the same shall be checked & confirmed
with charger manufacture.
The battery charger current rating shall be selected based on Boost charge current or float
charge current, whichever is higher. A spare capacity factor, on the basis of customer design
basis, shall be considered for future use. In the absence of any specific customer
requirements, a spare capacity factor of 1.25 (25 % spare capacity) can be considered.