110V and 48V Battery & Battery Charger Sizing Calculation for

BHANGURA 132/33KV NEW GRID SUBSTATION

 Project Name: Design, supply, installation, testing and commissioning of

230/132KV and 132/33KV substations, Northern Zone on Turnkey Basis.

 Contract No.: PGCB/KFW/2012.66.436/NZSS Dated: 24/12/2017

 Substation Name: BHANGURA 132/33KV NEW GRID SUBSTATION.

 Contractor: ENERGYPAC ENGINEERING LTD.

 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 132/11kV Substation at Bhangura. 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 10 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 V

Float charging voltage = 1.42 V

Maximum allowable system voltage

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

= 121 / 1.42
= 85.2

Minimum No. of cells required = 86.00

No. of cells selected = 92.00

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

= 92×1
= 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 400 AH
ii Charger Selected 100 A

Page-5
 Table -1

POWER Fire fighting

POWER BATTERY No of Continuous Closing Tripping Emergency
EQUIPMENT LOCATION & NO. NO. CONSUMPTION( Co efficient equipment Motor REMARKS
CONSUMPTION(Watt) VOLTAGE Panels Load Peak peak Lighting
Watt) peak

Emergency Light 30 Control room building 20 600 1 0 0 0 0 0 600

Annunciator 10 2 20 1 20 0 0 0 0 0
Meter 5 Line feeder Control panel 1 5 1 5 0 0 0 0 0
1
Indicator 2 ×(1 nos.) 3 6 1 6 0 0 0 0 0
C264 40 1 40 1 40 0 0 0 0 0

Auxiliary Relay 1 4 4 1 4 0 0 0 0 0
DSS 4 2 8 1 8 0 0 0 0 0
P14D 11 Line feeder Relay panel 1 11 1 11 0 0 0 0 0
P442 11 1 1 11 1 11 0 0 0 0 0
×(1 nos.)
P743 16 1 16 1 16 0 0 0 0 0
TCS 15 6 90 1 90 0 0 0 0 0
MVAJ 150 6 900 1 0 0 0 900 0 0

Annunciator 10 2 40 1 40 0 0 0 0 0
relay c264 40 1 80 1 80 0 0 0 0 0
Indicator 2 Transformer Feeder Control 3 12 1 12 0 0 0 0 0
2
panel×(2Nos) 110V
Meter 5 2 20 1 20 0 0 0 0 0
F650 25 1 50 1 50 0 0 0 0 0

P642 15 2 60 1 60 0 0 0 0 0
P14D 11 1 22 1 22 0 0 0 0 0
MVAJ 150 Transformer Feeder Relay 2 600 1 0 0 0 600 0 0
2
TCS(REL91324) 15 panel×(2Nos) 4 120 1 120 0 0 0 0 0
DSS 4 2 16 1 16 0 0 0 0 0
P743 16 1 32 1 32 0 0 0 0 0

F650 25 1 50 1 50 0 0 0 0 0
P14D 11 1 22 1 22 0 0 0 0 0
Indicator 2 2 8 1 8 0 0 0 0 0
Meter 2 1 4 1 4 0 0 0 0 0
TCS 33KV INCOMER × 2 2
15 2 60 1 60 0 0 0 0 0
MVAX31S1DE0754A
DSS
4 2 16 1 16 0 0 0 0 0
MVAA11R1CG0767C
MVAJ105RA0802A 150 2 600 1 0 0 0 600 0 0

132kV line
Disconnector 5 ISOLATOR(2)+Transformer 8 40 0.5 20 0 0 0 0 0
feeder(4)+33kV Incomer (2)

GCB Drive
10 3 30 0.5 15 0 0 0 0 0
Box(132KV)

VCB(33KV) 8 2 16 0.5 8 0 0 0 0 0

Fire Fighting
200 2 400 0.5 200 0 0 0 0 0
equipments

UPS for SAS 1500 1 1500 1 1500 0 0 0 0 0

Total power For five feeders 2566 0 0 2100 0 600

 Table-2
POWER
POWER Continuous Tripping Emergency
EQUIPMENT LOCATION & NO. NO. CONSUMPTION( Co efficient Closing Peak Motor REMARKS
CONSUMPTION Load peak Lighting
Watt)
Tripping
330 6 1980 1 0 1980
coil
132kV CB Single Pole 1Nos.
closing
330 3 990 1 0 990
coil
Tripping
330 4 1320 1 0 1320
coil
132kV CB Gang operated 2nos
closing
330 2 660 1 0 660
coil
Tripping
330 4 1320 1 0 1320
coil
33kV incoming Circuit Breaker 2nos
closing
330 2 660 1 0 660
coil
Power per Feeder 0 2310 4620 0 0
Simultaneity of feeders 1 0.2 1 0.2 1
Power for all 12 feeders 0 462 4620 0 0

Summation of table 1 & 2

Closing Tripping Emergency
Continuous Load
Peak peak Lighting
Table 1 2566 0 2100 600
Table 2 0 462 4620 0
Total Power 2566 462 6720 600
Total Current 23.33 4.20 61.09 5.45
 LOAD CYCLE TABLE & GRAPH

Period (min) Duration LOAD DESCRIPTION LOAD(A)

0--1 1 min Momentary tripping load+continuous load+emergency load (61.09+23.33+5.45)= 89.87 A

1--2 1 min Momentary closing load+continuous load+emergency load (4.2+23.33+5.45) = 32.98 A
2--60 58 min continuous load+emergency load (23.33+5.45) = 28.78 A
60--298 238 min continuous load (23.33) = 23.33 A
298--299 1 min Momentary tripping load+continuous load (61.09+23.33) = 84.42 A
299--300 1 min Momentary closing load+continuous load (4.2+23.33) = 27.53 A

LOAD
95.00
90.00
85.00
80.00
75.00
70.00
65.00
60.00
CURRENT(AMPERE)

55.00
50.00
45.00
LOAD
40.00
35.00
30.00
25.00
20.00
15.00
10.00
5.00
0.00
0
6
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
126
132
138
144
150
156
162
168
174
180
186
192
198
204
210
216
222
228
234
240
246
252
258
264
270
276
282
288
294
300
TIME(MINUTE)
Nominal Temperature 30ᵒC Minimum Cell Cell Mfg: Cell Type:
Voltage
Lowest 20ᵒC HBL Nickel Cadmium
1V
Highest 40ᵒC

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs
Section 1-First 1 Period(s) Only-if A2 is greater than A1. Go to section 2
1 A1 A1-A0 M1 t=M1
89.87 89.87 1.00 1.00 0.505 45.38
Total 45.38

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs
Section 2-First 2 Period(s) Only-if A3 is greater than A2. Go to section 3
1 A1 A1-A0 M1 t=M1+M2
89.87 89.87 1.00 2.00 0.55 49.43
2 A2 A2-A1 M2 t=M2
32.98 -56.89 1.00 1.00 0.505 -28.73
Total 20.70

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs
Section 3-First 3 Period(s) Only-if A4 is greater than A3. Go to section 4
1 A1 A1-A0 M1 t=M1+M2+M3
89.87 89.87 1.00 60.00 1.325 119.08
2 A2 A2-A1 M2 t=M2+M3
32.98 -56.89 1.00 59.00 1.32 -75.09
3 A3 A3-A2 M3 t=M3
28.78 -4.20 58.00 58.00 1.315 -5.52
Total 38.46
(1) (2) (3) (4) (5) (6) (8)
Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs
Section 4-First 4 Period(s) Only-if A5 is greater than A4. Go to section 5
1 A1 A1-A0 M1 t=M1+M2+M3+M4
89.87 89.87 1.00 298.00 4.96 445.76
2 A2 A2-A1 M2 t=M2+M3+M4
32.98 -56.89 1.00 297.00 4.94 -281.04
3 A3 A3-A2 M3 t=M3+M4
28.78 -4.20 58.00 296.00 4.92 -20.66
4 A4 A4-A3 M4 t=M4
23.33 -5.45 238.00 238.00 3.96 -21.582
Total 122.47

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs
Section 5-First 5 Period(s) Only-if A6 is greater than A5. Go to section 6
1 A1 A1-A0 M1 t=M1+M2+M3+M4+M5
89.87 89.87 1.00 299.00 4.98 447.55
2 A2 A2-A1 M2 t=M2+M3+M4+M5
32.98 -56.89 1.00 298.00 4.96 -282.17
3 A3 A3-A2 M3 t=M3+M4+M5
28.78 -4.20 58.00 297.00 4.94 -20.75
4 A4 A4-A3 M4 t=M4+M5
23.33 -5.45 238.00 239.00 3.98 -21.691
5 A5 A5-A4 M5 t=M5
84.42 61.09 1.00 1.00 0.505 30.85045
Total 153.79

(1) (2) (3) (4) (5) (6) (8)

Period Load(Amperes) Change in Load Duration of Period Time to End of Capacity Rating Required Section
(Amperes) (Minutes) section(Minutes) Factor (kt) Size(3)×(6)
=Rated Amp Hrs
Section 6-First 6 Period(s) Only-if A7 is greater than A6. Go to section 7
1 A1 A1-A0 M1 t=M1+M2+M3+M4+M5+M6
89.87 89.87 1.00 300.00 5 449.35
2 A2 A2-A1 M2 t=M2+M3+M4+M5+M6
32.98 -56.89 1.00 299.00 4.98 -283.31
3 A3 A3-A2 M3 t=M3+M4+M5+M6
28.78 -4.20 58.00 298.00 4.96 -20.83
4 A4 A4-A3 M4 t=M4+M5+M6
23.33 -5.45 238.00 240.00 4 -21.8
5 A5 A5-A4 M5 t=M5+M6
84.42 61.09 1.00 2.00 0.55 33.5995
6 A6 A6-A5 M6 t=M6
27.53 -56.89 1.00 1.00 0.505 -28.73
Total 128.28
Maximum section size = 153.79 AH

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

factor x Aging factor

Battery size calculated = 194.54435 AH

Battery size selected = 400 AH

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

= (211 + 452 + 160) Watts [ values were taken from Table 1]

= 823 Watts

= 7.48 Amp.

Battery size selected = 400 AH

Battery can backup the above mentioned load upto (400 / 7.48) = 53.4629 Hours

Which Fulfills PGCB’s requirement.

Page-11
FLOAT CUM BOOST CHARGER SIZING CALCULATION

SELECTED BATTERY SIZE = 400 AH

DC Nominal Voltage = 110 V
A) FLOAT CHARGER RATING
Float Charger Rating = (Continuous load current + Float charging current)
Continuous Load Current = 23.33 A
Float Charging Current = 2 mA per AH rating of battery
= 0.8 A
Float Charger Rating Calculated = 24.13 A
Design Margin = 10%
Rating of Battery Charger = 26.543
A

B) BOOST CHARGER RATING

Boost Charger Rating = 20% of AH Rating of battery
Boost Charger Rating Calculated = 80 A
Design Margin = 10%
Rating of Battery Charger = 88 A
Battery Charger Rating Selected = 100 A

RESULT

No. of Battery Cells = 92 Nos.

AH Capacity = 400 AH.

Float cum Boost Charger rating = 100A at 110V DC

Page-12
 ANNEXURE-1
DVR Calculation
Number of Boost Voltage Total Boost Nominal Load % of Max Max load Required Voltage Voltage Drop at
No of Diode
Cell Per cell Voltage Voltage Voltage Voltage Drop At DVR Single Diode
110VDC
92 1.53 140.76 110 5 115.5 25.26 0.8 31.58
 ANNEXURE-2

Local Station- UPS

Sr.No Equipment Description Power Req No of Unit Actual

Consumption
1 HMI PC 300 3 900
2 Disturbance Recorder 100 1 100
3 Ethernet Switches 40 6 240
4 TFT Monitors 60 3 180
5 Laser Color Printer 190 2 380
6 GPS Time Sync Equipment 15 1 15
7 Gateway 15 2 30
TOTAL 1845 W

Power Factor = 0.8

KVA Requirement = 2.30625 kVA

Considering 85% Efficiency

And avg. diversity factor = 1273.05 W
Of 0.6 of UPS

Hence, Load on battery(W) = 1280 W