RFE-1-BTA-ECE-IDO-001-REVB Batteries Sizing PDF

PLANTA DE RESERVA FRA
DE GENERACIN DE ETEN S.A
PROYECTO
PROJECT
RESERVA FRA ETEN

CONTRATISTA
CONTRACTOR
TTULO
TITLE
DC BATTERIES AND DISTRIBUTION BOARDS

CALCULATION
N DE DOCUMENTO PROYECTO
PROJECT DOCUMENT N
RFE-1-BTA-ECE-IDO-001
REV
FECHA
DATE
15/01/2014
EDITADO PARA
ISSUED FOR
PRV
PRV
REALIZADO
DONE BY
REVISADO
CHECKED BY
For Design
JSA
APROBADO
APPROVED BY
ESTE DOCUMENTO CONTIENE INFORMACIN PROPIETARIA Y NO PUEDE SER DUPLICADO, PROCESADO O CEDIDO A TERCEROS PARA UN USO DISTINTO AL DE
ESTE PROYECTO Y EL OBJETO PARA EL QUE HA SIDO PREVISTO SIN LA AUTORIZACIN ESCRITA DE COBRA.
THIS DOCUMENT CONTAINS PROPIETARY INFORMATION AND CAN NOT BE DUPLICATED, PROCESSED OR DISCLOSED TO THIRD PARTIES FOR ANY USE OTHER
THAN THIS PROJECT AND THE PURPOSE FOR WHICH IT IS INTENDED FOR WITHOUT THE WRITTEN CONSENT OF COBRA.
CALCULATION DC BATTERIES AND BOARDS

Rev B
Pg/Page 2 de/of 15
CONTROL DE MODIFICACIONES/CHANGE LOG

Revisin
Fecha
Modificaciones
Revision
Date
Modifications
13/12/2013
FIRST EDITION
15/01/2014
COBRA COMMENTS
Este documento contiene informacin propiedad de Cobra y est sujeto a las restricciones detalladas en la pgina de portada.
La nica copia controlada de este documento es la incluida en la intranet de Cobra.
This document contains proprietary information of Cobra and is subject to the restrictions set forth on the title page.
The only controlled copy of the document is located on the Cobra intranet.

Rev B
Pg/Page 3 de/of 15
NDICE
1.
OBJECT .............................................................................................................................. 4
2.
REFERENCE DOCUMENTATION ...................................................................................... 5
3.
GENERAL INFORMATION ................................................................................................. 6

3.1. SITE ........................................................................................................................... 6
3.1.1. Climate conditions .................................................................................... 6
4.
APPLICABLE STANDARDS AND REGULATIONS ........................................................... 7
5.
DC DISTRIBUTION SYSTEM DESIGN ............................................................................... 8

5.1. DC LOAD LIST ........................................................................................................... 8
5.2. CALCULATION OF NUMBER OF CELLS .................................................................. 8
5.3. BATTERY SIZING ...................................................................................................... 9
5.4. RECTIFIER SIZING.................................................................................................. 11
5.5. SHORT CIRCUIT CURRENT IN DC DISTRIBUTION BOARD ................................. 12
6.
CONCLUSIONS ................................................................................................................ 14
7.
ANNEXES ......................................................................................................................... 15

1.
Rev B
Pg/Page 4 de/of 15
OBJECT
The purpose of the present document is to size the battery capacity and power rectifier changer
of DC Distribution Boards to supply to the ETN Power Generation Plant projected in Peru, with
an approximate net power of 230 MW.
The sizing of the Control Room UPS is also determined in Annex 2. There will be no DC power
consumption in the Control Room, so that the size of the battery shall be defined by the
manufacturer of the UPS system according to the size of the UPS itself.
This revision B is a preliminary calculation. Later on, the DC System supplier would develop a
more precise calculation with the actual battery cell data and the final load lists.

2.
Rev B
Pg/Page 5 de/of 15
REFERENCE DOCUMENTATION
The following documentation shall be used as a reference in this document:

Specific reference documents:
RFE-1-BTA-EIP-IDO-001 : DC System Specification
Generic reference documents:

The documents quoted in the above references.

3.
Rev B
Pg/Page 6 de/of 15
GENERAL INFORMATION
3.1. SITE
The plant shall be located a few kilometres from the municipal district of Reque in the province of
Chiclayo in the department of Lambayeque Peru.
3.1.1. Climate conditions
The following climate conditions are adopted for the design:
Mean temperature ............................................................................................ 21.7 C

Ambient temperature range .............................................................. 14.6 C 33.9 C
Relative humidity ............................................................................................... 73.2 %
Relative humidity range ...................................................................... 64.9 % - 81.0 %
Atmospheric pressure .............................................................................. 1013.9 mbar
Elevation ................................................................................................... +77.5 m asl
Location ..................................................................... Near to the sea (approx. 10 Km)
Maximum wind speed ..................................................................................... 95 km/h
Prevailing wind direction ................................................................... 179.3 from SSE
Average annual rainfall ................................................................................. 77.5 mm
Average monthly rainfall with El Nio phenomenon ..................................... 173 mm
Desert environment: Dirty Ambient .................................................................. 50g/m3

4.
Rev B
Pg/Page 7 de/of 15
APPLICABLE STANDARDS AND REGULATIONS
The battery capacity shall be calculated in accordance with the following codes and standards:
IEEE Std 485: Recommended Practice for Sizing Lead-Acid Batteries for Stationary
Applications.
IEEE Std 1184: Guide for Batteries for Uninterruptible Power Supply Systems

5.
Rev B
Pg/Page 8 de/of 15
DC DISTRIBUTION SYSTEM DESIGN
5.1. DC LOAD LIST

The individual DC loads supplied by the battery during the duty cycle may be classified as
continuous or non-continuous.
Annex 1 of this document includes a table with a DC load list of the plant.
5.2. CALCULATION OF NUMBER OF CELLS

From IEEE std 1184 typical voltages of the lead batteries are:
Open Circuit (UN): ........................................................................................... 2,1 V/Cell

Float (UFLOAT) ...................................................................................... 2.15 to 2.4 V/Cell
Equalizing (UEQUAL) ............................................................................... 2.3 to 2.5 V/Cell
Cut Off (UC-O) .................................................................................... 1.67 to 2.10 V/Cell
The detailed calculation have to take the actual selected batteries data.
In the other hand, the limits for the DC system are:
Nominal (VN)......................................................................................................... 125 V

Maximum (VMAX) ............................................................................... 125 +10% = 137 V
Minimum (VMIN) ............................................................................... 125 -15% = 106.3 V
Maximum voltage drop (VDC) .......................................................... 5% 125 V = 6.25 V
Therefore the number of battery cells (NE) will be set from the following relationships, taking into
account the actual battery voltages:
a)
Considering equalization voltage as the maximum system voltage
NE
VMAX
137 V
57 cells
VEQUAL
2.4 V
b) Considering the battery Cut-Of voltage as the minimum system voltage
NE
VMIN VDC 106.3 6.25
60 cells
VC O
1.85
Or the end-of-discharge voltage, with a known number of cells is
U C O
VMIN VDC 106.3 6.25
1.975 V
NE
57

Rev B
Pg/Page 9 de/of 15
The higher end of discharge voltage, the higher nominal battery capacity will be needed.
c) If the battery and charger are isolated from the loads during equalizing, the float voltage
shall be considered as the maximum battery voltage
NE
VMAX
137 V
60 cells
VFLOAT 2.27 V
5.3. BATTERY SIZING

To determine the battery capacity, the duty cycle diagram of the batteries is used. The resultant
current in each operation mode is determined in annex 1.
The UPS loads are essentially static loads that maintain their power basically constant through
the whole discharge time.
For the DC loads it is assumed three peak consumptions due to the actuators (breakers,
contactors, and so).
The final result is as follows:
Time
(min)
Duration of
period
(minutes)
Total Load at
125 VDC
(A)
0 to 1
M1= 1
A1 = 540
1 to 14
M2= 13
A2= 450
14 to 15
M3 = 1
A3= 530
15 to 29
M4 = 14
A4= 450
29 to 30
M5 = 1
A5 = 530
And the duty cycle diagram is as follows.

Rev B
Pg/Page 10 de/of 15
Based on the duty cycle diagram, the battery capacity will be determined, using the standard
chart and the specific cell data.
The following is an example with a hypothetical cell battery with its own Kt factors.
Period
Load
Change in Load
Duration of
Period
Time to End of Section
Capacity at
T Min Rate
(A)
(A)
(minutes)
(minutes)
Factor (Kt)
Section 1 - First Period Only - If A2 is greater than A1, go to Section 2

1 A1 =
540 A1-0 =
+540 M1 =
1 T = M1
Section 2 - First Two Period Only - If A3 is greater than A2, go to Section 3

1 A1 =
A1-0 =
0,00 M1 =
T = M1+M2
2 A2 =
A2-A1 =
0,00 M2 =
T = M2
0
0
Section 3 - First Three Period Only - If A4 is greater than A3, go to Section 4

1 A1 = 540
A1-0 =
+540 M1 = 1
T = M1+M2+M3
2 A2 = 450
A2-A1 =
-90 M2 = 13 T = M2+M3
3 A3 = 530
A3-A2 =
+80 M3 = 1
T = M3
Section 4 - First Four Period Only - If A5 is greater than A4, go to Section 5

T = M1+M2++M4
1 A1 =
A1-0 =
0,00 M1 =
2 A2 =
A2-A1 =
0,00 M2 =
T = M2+M3+M4
3 A3 =
A3-A2 =
0,00 M3 =
T = M3+M4
15
14
1
Required Section
Size
(Amp * Hrs)
Pos
Neg
Value
Values
1.1
Sub. Total
594
594
Sub. Total
0,00
1.5
1.5
1.1
Sub. Total
Total
810
-135
88
898
763
0
0
0
-135

Period
Rev B
Pg/Page 11 de/of 15
Load
Change in Load
Duration of
Period
Time to End of Section
Capacity at
T Min Rate
(A)
(A)
(minutes)
(minutes)
Factor (Kt)
4 A4 =
A4-A3 =
0,00
M4 =
T = M4
Section 5 - First Four Period Only - If A6 is greater than A5, go to Section 5

T = M1++M5
1 A1 = 540
A1-0 =
+540 M1 = 1
2 A2 = 450
A2-A1 =
-90 M2 = 13 T = M2++M5
3 A3 = 530
A3-A2 =
+80 M3 = 1
T = M3+M4+M5
4 A4 = 450
A4-A3 =
-80 M4 = 14 T = M4+M5
5 A5 = 530
A5-A4 =
+80 M5 = 1
T = M5
Required Section
Size
(Amp * Hrs)
Pos
Neg
Value
Values
30
29
16
15
1
Sub. Total
Total
0,00
0,00
1.75
1.75
1.5
1.5
1.1
Sub. Total
Total
945
-157.5
120
-125
88
1153 -282.5
870.5
The maximum section size, therefore, is 870.5 Ah

Once the battery capacity in Ah (Ampere by hour) is evaluated, the following correction factors
shall be applied:
Aging factor: A factor of 1,25 will be considered as aging factor, so that the load at the
end of its useful life of the battery will be the expected load.
Design margin: A factor of 1,10 will be expected as reserve for a future expansion.
Temperature correction factor: The standard temperature for rating cell capacity is
25C. If the electrolyte has a different temperature, a temperature correction factor will
be applied.
C ( Ah) Ah 1,25 1,10 1

C ( Ah) 870.5 1,25 1,10 1 1197 Ah
To comply with the above criteria, the battery capacity required of each battery group will be
1197 Ah. The commercial battery capacity next larger than that is 1200 Ah.
5.4. RECTIFIER SIZING

The output rated power of the battery charger rectifier is determined taking into account that the
battery charger rectifier will supply the total rated power required for the direct current of the
plant.
The sizing of the rated power of the battery charger rectifier will be set so that in case of
unavailability of one of the rectifiers, the other equipment is able to supply the total power

Rev B
Pg/Page 12 de/of 15
demanded by the direct current services of the plant, and recharge the group of batteries in
maximum twelve (12) hours.
The rectifier size is determined as per IEEE Std 946 chapter 6.2.
To determine the output current of the battery charger rectifier, the efficiency of the batteries as a
result of internal losses should be taken into account. In addition, a minimum design margin of
20% should be considered for a future expansion.
C ( Ah )
1 1
Irec car 1,1
I LC
k1 k 2
1200 Ah
Irec car 1.1

540 A 1 1 650 A
12h
where:
Irec-char: Battery charger capacity (A).
C (Ah): Battery capacity required during the duty cycle (Ah).
T: Recharging time (h) to approximately 95% of capacity.
k1: Correction factor for temperature different from (25 C).
k2: Correction factor for altitude higher than 1.000 m.
ILC: Continuous load current supplied by the rectifier-charger (A).
1.1: is the constant that compensates for the battery losses.
To comply with the above criteria, the output power of each rectifier-battery charger will be
approximately of 100 kVA.
5.5. SHORT CIRCUIT CURRENT IN DC DISTRIBUTION BOARD

According to IEEE 946-1992, the short circuit current is the sum of the contribution of the battery,
battery charger rectifier contribution, and the contribution of the motors. Therefore, the short
circuit current DC Distribution Board will be:
I SC DC I BAT I CAR I MOT

where:
ISC-DC: Short circuit current in the DC Distribution Board (A).
IBAT: Short circuit current contributed by the battery (A).
ICAR: Short circuit current contributed by the charger (A).

Rev B
Pg/Page 13 de/of 15
IMOT: Short circuit current contributed by the DC Motors (A).

To determine the short circuit current of the DC Distribution Board will be considered an
oversizing factor of 115%.

6.
Rev B
Pg/Page 14 de/of 15
CONCLUSIONS
Based on the above results, the technical data of the DC Distribution Boards are as follows:
Input rated voltage:............................................................................................ 480 V
Output rated voltage: ................................................................................... 125 V DC
Minimum battery voltage: ......................................................................... 112.5 V DC
Battery capacity: ............................................................................................ 1200 Ah
Recharging time: .................................................................. 12 Hours (95% charged)
Output rated power of rectifier-battery charger: ............................................ 100 kVA

7.
Rev B
Pg/Page 15 de/of 15
ANNEXES
Annex 1: Plant DC and UPS Load List

Annex 2: Control Room UPS Load List
CALCULATION DC BATTERIES AND

BOARDS
ANNEX 1:
PLANT DC AND UPS LOAD LIST
Rev. B
ANNEX 1
Page 1 of 2
DESCRIPTION
1,00
1,00
3,00
3,00
3,00
4,00
4,00
5,00
27,70
220
220
220
220
220
220
127
220
125
125
MANDO - CCM 1BMA52
MANDO - CABINA 1BFA51/53
MANDO CABINA 1BMA52
MANDO - CABINA 1BBA51

(MEDIA TENSIN)
PENDIENTE
PENDIENTE
PENDIENTE
PENDIENTE
125
18,40
46,96
1,50
1,50
1,50
3,00
1,00
1,50
0,20
0,20
1,50
1,50
1,50
1,50
1,50
3,00
1,00
1,50
0,20
0,20
1,50
1,50
5,00
3,53
3,53
3,53
4,71
4,71
1,18
1,18
1,76
1,18
0,35
0,35
12,00
12,00
12,00
24,00
8,00
12,00
1,60
1,60
12,00
12,00
40,00
26,74
16,04
16,04
16,04
21,39
37,05
5,35
5,35
8,02
5,35
1,60
1,60
1,60
1,60
12,00
12,00
12,00
24,00
8,00
12,00
1,60
1,60
12,00
12,00
40,00
41,24
24,74
24,74
24,74
32,99
32,99
8,25
8,25
12,37
8,25
2,47
2,47
2,47
2,47
537,18
18,00
18,00
18,00
36,00
12,00
18,00
1,60
1,60
18,00
18,00
60,00
41,24
24,74
24,74
24,74
32,99
32,99
8,25
8,25
12,37
8,25
2,47
2,47
2,47
2,47
Irated (A)
Irated (A) @
0 - 1 min
@ Un
125 VDC
(assuming perfomance inverter 97% )
450,78
12,00
12,00
12,00
24,00
8,00
12,00
1,60
1,60
12,00
12,00
40,00
41,24
24,74
24,74
24,74
32,99
32,99
8,25
8,25
12,37
8,25
2,47
2,47
2,47
2,47
1 - 14 min
532,38
18,00
18,00
18,00
36,00
8,00
18,00
1,60
1,60
18,00
18,00
60,00
41,24
24,74
24,74
24,74
32,99
32,99
8,25
8,25
12,37
8,25
2,47
2,47
2,47
2,47
14 - 15 min
450,78
12,00
12,00
12,00
24,00
8,00
12,00
1,60
1,60
12,00
12,00
40,00
41,24
24,74
24,74
24,74
32,99
32,99
8,25
8,25
12,37
8,25
2,47
2,47
2,47
2,47
15-29 min
532,38
18,00
18,00
18,00
36,00
8,00
18,00
1,60
1,60
18,00
18,00
60,00
41,24
24,74
24,74
24,74
32,99
32,99
8,25
8,25
12,37
8,25
2,47
2,47
2,47
2,47
29-30 min
TOTAL DC LOADS
TOTAL DC LOADS + GENERAL UPS + 20% SPARE
125
MANDO - INTERRUPTOR
GENERADOR
PENDIENTE
125
125
125
125
125
125
5,00
1,50
1,00
220
220
125
0,30
220
MANDO - DIESEL
MANDO - TRANSFORMADOR
1BAT10
MANDO - TRANSFORMADOR
1BBT51
MANDO TRANSFORMADOR
1BFT51 (MT/BT)
MANDO TRANSFORMADOR
1BFT53 (MT/BT)
MANDO - SUBESTACIN
5,88
32,59
0,30
220
0,35
0,30
220
0,35
POT. (kVA)
0,30
POT. (kW)
220
VOLTAGE
Un (V)
PENDIENTE
PENDIENTE
PENDIENTE
PENDIENTE
PENDIENTE
PENDIENTE
1EGA11CF001-P01
CAUDALIMETRO 1 RED
APORTE COMBUSTIBLE
CAUDALIMETRO 2 RED
1EGA21CF001-P01
APORTE COMBUSTIBLE
CAUDALIMETRO 1 RED
1GAF11CF001-P01
APORTE AGUA BRUTA
CAUDALIMETRO 2 RED
1GAF21CF001-P01
APORTE AGUA BRUTA
PENDIENTE
PLC SISTEMA PTA
PENDIENTE
PLC SISTEMA PCI
PLC SISTEMA AIRE
PENDIENTE
COMPRIMIDO
PLC GRUPO DIESEL DE
PENDIENTE
EMERGENCIA
PENDIENTE
RACK 1 DEL DCS
PENDIENTE
RACK 2 DEL DCS
PENDIENTE
RACK TELECOMUNICACIONES
PENDIENTE
GENERADOR AUXILIAR (SAI)
1BRB11
TURBINA GAS (UPS)
SISTEMA DE MONITORIZACIN
PENDIENTE
DE EMISIONES (CEMS)
TOTAL LOAD OF THE GENERAL UPS
DC LOADS (DIRECT FROM BATTERIES)
GENERAL UPS
KKS

BOARDS
Rev. B
ANNEX 1
Page 2 of 2

BOARDS
ANNEX 2:
CONTROL ROOM UPS LOAD LIST
Rev. B
ANNEX 2
Page 1 of 2

BOARDS
Rev. B
ANNEX 2
KKS
CONTROL ROOM UPS
DESCRIPTION
Page 2 of 2
VOLTAGE
POT. (kW)
POT. (kVA)
PENDIENTE
CENTRALITA
CONTRAINCENDIOS
220
0,50
0,59
2,67
PENDIENTE
SISTEMA MEGAFONIA
220
1,50
1,76
8,02
PENDIENTE
RACK TELECOMUNICACIONES
220
1,50
1,76
8,02
PENDIENTE
SISTEMA CCTV
220
1,50
1,76
8,02
PENDIENTE
ESTACIN DE OPERACIN
220
0,70
0,82
3,74
127
0,50
0,59
4,63
220
0,50
0,59
2,67
220
0,50
0,59
2,67
220
0,50
0,59
2,67
PENDIENTE
PENDIENTE
PENDIENTE
PENDIENTE
ESTACIN OPERACIN DE LA
TURBINA GAS
ESTACIN DE OPERACIN
CEMS
ESTACIN DE OPERACIN
GENERADOR AUXILIAR
ESTACIN DE INGENIERA,
HISTRICOS Y ALARMAS
PENDIENTE
SERVIDOR DE HISTRICOS
220
0,50
0,59
2,67
PENDIENTE
SISTEMA SINCRONIZACIN
HORARIA (GPS)
220
0,30
0,35
1,60
PENDIENTE
IMPRESORA B/N OPERACIN
220
1,20
1,41
6,42
220
0,20
0,24
1,07
127
0,60
0,71
5,56
10,50
12,35
15,75
PENDIENTE
PENDIENTE
IMPRESORA B/N REGISTRO

ALARMAS
SWITCHES DE LA TURBINA
GAS
TOTAL UPS LOADS

UPS OUTPUT DESIGN POWER (kVA) WITH 20% SPARE, AND PF =80%

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PLANTA DE RESERVA FRA

DE GENERACIN DE ETEN S.A

RESERVA FRA ETEN

DC BATTERIES AND DISTRIBUTION BOARDS

CALCULATION DC BATTERIES AND BOARDS

CONTROL DE MODIFICACIONES/CHANGE LOG

CALCULATION DC BATTERIES AND BOARDS

REFERENCE DOCUMENTATION ...................................................................................... 5

GENERAL INFORMATION ................................................................................................. 6

APPLICABLE STANDARDS AND REGULATIONS ........................................................... 7

DC DISTRIBUTION SYSTEM DESIGN ............................................................................... 8

CALCULATION DC BATTERIES AND BOARDS

CALCULATION DC BATTERIES AND BOARDS

The following documentation shall be used as a reference in this document:

RFE-1-BTA-EIP-IDO-001 : DC System Specification

Generic reference documents:

CALCULATION DC BATTERIES AND BOARDS

Mean temperature ............................................................................................ 21.7 C

CALCULATION DC BATTERIES AND BOARDS

APPLICABLE STANDARDS AND REGULATIONS

CALCULATION DC BATTERIES AND BOARDS

DC DISTRIBUTION SYSTEM DESIGN

5.1. DC LOAD LIST

5.2. CALCULATION OF NUMBER OF CELLS

Open Circuit (UN): ........................................................................................... 2,1 V/Cell

Nominal (VN)......................................................................................................... 125 V

Considering equalization voltage as the maximum system voltage

b) Considering the battery Cut-Of voltage as the minimum system voltage

VMIN VDC 106.3 6.25

Or the end-of-discharge voltage, with a known number of cells is

VMIN VDC 106.3 6.25

CALCULATION DC BATTERIES AND BOARDS

5.3. BATTERY SIZING

And the duty cycle diagram is as follows.

CALCULATION DC BATTERIES AND BOARDS

Time to End of Section

Section 1 - First Period Only - If A2 is greater than A1, go to Section 2

Section 2 - First Two Period Only - If A3 is greater than A2, go to Section 3

Section 3 - First Three Period Only - If A4 is greater than A3, go to Section 4

Section 4 - First Four Period Only - If A5 is greater than A4, go to Section 5

CALCULATION DC BATTERIES AND BOARDS

Time to End of Section

Section 5 - First Four Period Only - If A6 is greater than A5, go to Section 5

The maximum section size, therefore, is 870.5 Ah

C ( Ah) Ah 1,25 1,10 1

5.4. RECTIFIER SIZING

CALCULATION DC BATTERIES AND BOARDS

Irec car 1.1

5.5. SHORT CIRCUIT CURRENT IN DC DISTRIBUTION BOARD

I SC DC I BAT I CAR I MOT

CALCULATION DC BATTERIES AND BOARDS

IMOT: Short circuit current contributed by the DC Motors (A).

CALCULATION DC BATTERIES AND BOARDS

Input rated voltage:............................................................................................ 480 V

Output rated voltage: ................................................................................... 125 V DC

Minimum battery voltage: ......................................................................... 112.5 V DC

Battery capacity: ............................................................................................ 1200 Ah

Recharging time: .................................................................. 12 Hours (95% charged)

Output rated power of rectifier-battery charger: ............................................ 100 kVA

CALCULATION DC BATTERIES AND BOARDS

Annex 1: Plant DC and UPS Load List

CALCULATION DC BATTERIES AND

MANDO - CCM 1BMA52