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SHEET ( i ) OF (v)
DC SYSTEM
DESIGN GUIDE
FOR
DC SYSTEM
FLOPPY NO
FILE NAME
: TCE.M6-EL-FP-DOC-006
: M6-6000.DWG
REV.NO
R1
R2
R3
ISSUE
INITIALS
SIGN
INITIALS
SIGN
INITIALS
SIGN
PPD.BY
CPS
Sd/-
RRN
Sd/-
RRN
Sd/-
CKD.BY
DKB/DDRC
Sd/-
VS
Sd/-
VS
Sd/-
APP.BY
DKB
Sd/-
UAK
Sd/-
UAK
Sd/-
DATE
92-09-04
97-03-31
INITIALS
SIGN
R3
99-03-02
FORM NO. 020R2
SECTION:
REV. STATUS
DC SYSTEM
REVISION STATUS
REV. NO
DATE
R3
99-03-02
DESCRIPTION
ISSUE
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FORM NO. 120 R1
SECTION:
CONTENTS
DC SYSTEM
CONTENTS
PART-A
LEAD ACID BATTERY
SL.NO.
1.0
TITLE
SCOPE
SHEET NO.
2
2.0
3.0
4.0
QUANTITIES OF BATTERIES
5.0
6.0
INSTALLATION OF BATTERY
11
7.0
REFERENCES
13
14
16
18
19
20
21
23
24
31
32
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CONTENTS
DC SYSTEM
CONTENTS
PART-B
NICAD BATTERY
SL.NO.
1.0
TITLE
SCOPE
2.0
35
3.0
PERFORMANCE CHARECTERISTICS
35
4.0
38
5.0
MODE OF OPERATION
39
6.0
NUMBER OF CELLS
40
7.0
41
8.0
INSTALLATION
42
9.0
43
10.0
44
11.0
REFERENCES
45
SHEET NO.
35
46
PREFERRED DIMENSIONS
47
48
TEMPERATURE CORRECTION
FACTOR CURVES
APPENDIX-2 SAMPLE CELL SIZING CALCULATION
CELL SIZING WORK SHEET
64
67
69
71
72
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CONTENTS
SHEET (v ) OF (v)
DC SYSTEM
CONTENTS
PART-C
BATTERY CHARGER
SL.NO.
TITLE
SHEET NO.
1.0
SCOPE
75
2.0
RECOMMENDED PRACTICE
75
3.0
DISCUSSION
79
4.0
ENCLOSURES
i)
FLOAT CUM BOOST
CHARGER WITH
2 x 100% BATTERIES
ii)
iii)
TCE.M2-EL-CW-S-2631 R0
TCE.M2-EL-CW-S-2632 R0
TCE.M2-EL-CW-S-2633 R0
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PART-A
LEAD ACID BATTERY
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1.0
SCOPE
This design guide outlines the recommendation for the determination
of voltage level, capacity, quantities and installation of DC battery of
lead acid storage type required for providing DC power supply to
essential services in the plant when the normal power supply fails.
This also gives consideration to the safe shut down of the plant as
well as human safety.
1.1
This section (Part A) of this guide pertains to lead acid batteries and
also includes a few recommendations applicable to NiCad batteries
also like selecting voltage levels. The sizing criteria for Nickel
Cadmium batteries are dealt in Part B of this design guide and
Part C of this guide covers details about Battery chargers .
2.0
2.1
The plante type cells are more rugged, need less maintenance and
have a life expectancy of about 15-18 years, which is 5-7 years
longer than that for tubular type. However, the plante type battery is
costlier than the tubular type. All the manufacturers make tubular
cells while very few manufacturers make plante cell.
2.2
The cells with tubular plate construction are smaller in size than the
plante type for a given AH rating.
2.3
2.4
2.5
DC SYSTEM
SECTION:
WRITEUP
SHEET
OF 79
The operating experience of the MF-VR and LM type cells for large
capacities is limited and very few manufacturers make the same.
Hence the sizing of these cells is not being discussed in the present
guide and use of these cells may be decided on case to case basis.
2.7
3.0
3.1
The voltage level selection for the plant shall consider the following
aspects :
3.2
a)
Quantum of power
b)
c)
For the same power requirement, the battery room size, and battery
cost with higher voltage will be higher than those with lower voltage.
However, the lower voltage requires higher current for the loads and
hence to meet this current and to limit the voltage drop within limits
cable sizes will be higher than those with higher voltage. Considering
all the aspects following voltage levels are recommended.
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b)
I&C system
c)
d)
Switchyards
e)
110 V DC/220 V DC
3.2.2
220 V DC
Industrial Plants
a)
220 V DC
b)
110 V DC
c)
30 V DC
d)
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4.0
4.1
4.1.1
4.1.2
QUANTITIES OF BATTERIES
Power Plants
a) In case of unit sizes upto 250 MW, each unit shall be provided
with one battery and also, a separate battery shall be provided
for the common services of these units and switchyard load. The
unit and common services batteries shall be sized to cater one
unit and station service loads so that one serves as a standby to
the other.
b)
c)
d)
For large power units (500 MW and above) and nuclear power plants,
for each unit, the 220V DC unit loads shall be divided into two
categories, e.g.
a)
b)
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4.1.3
4.1.4
4.2
4.3
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5.0
5.1
5.2
5.2.1
Duty cycle
End of the duty cycle voltage
Temperature correction factor
Compensation for ageing
Design margin
Duty cycle
a)
b)
c)
The duration for which each type of D.C. load will have to be
supplied by battery when the normal power supply fails is
different. The same may be continuous or for short time duration
or momentary. In a typical power plant the DC power, control &
protection loads and their classification based on duration for
which they need to be supplied are as follows.
Time duration
i)
Upto 1 minute
Loads (Amperes)
*
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ii)
*
*
*
iii)
*
*
*
*
*
iv)
Upto 10 hours
*
*
d)
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e)
5.2.2
b)
c)
ii)
DC SYSTEM
SECTION:
WRITEUP
SHEET
10
OF 79
by
Min. allowable D.C. voltage + Cable drop
------------------------------------------------No. of cells
d)
Sl.
No
1
5.2.3
e)
f)
DC SYSTEM
SECTION:
WRITEUP
SHEET
11
OF 79
Correction factor
=
/
K
\
for the lowest
| 1 + -------- (27-T) |
expected electrolyte
|
100
|
temperature, Tdeg.C
\
/
The factor 'K' for plante cells is 0.9 and for tubular, 0.43. The
minimum electrolyte temperature (T) shall be considered as 10deg.C
higher than the minimum ambient air temperature at site.
5.2.4
5.2.5
Design margin
When the D.C. loads are more or less final at the time of battery
sizing for tender specification purposes and/or the battery sizing is
being done for a similar plant already executed, no design margin is
considered necessary. If the sizing is being done for a new type of
project or with very little confirmed loads, a design margin of 10 to
15% shall be provided over the final capacity arrived.
While sizing the battery for nuclear power plant applications, it shall
be noted that the "margins" required by IEEE STD.323-1273. 6.3.15
& 6.3.3 are to be applied during "Qualification" and are not related to
"design margin".
5.3
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6.0
INSTALLATION
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
During float or boost charging of the lead acid battery hydrogen gas
is generated. The volume of hydrogen gas generated depends on the
amount of charging current. Also, the float current demand of a fully
charged battery will double approximately for every 10deg.C rise
above the base temperature of 27deg.C. Each fully charged cell
produces 4.5 x 10-4 Cu.m (0.016 Cu.pt) hydrogen gas per hour per
charging amperes in an ambient of 25deg.C to 27deg.C. Hydrogen
explosive concentration is reached if the explosives mixture is three
percent of the volume of room air.
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6.9
6.10
7.0
REFERENCES
7.1
IS:1651-1991
7.2
IS:1652-1991
7.3
7.4
IS:8320-1272
7.5
IS:1885-1965
7.6
7.7
7.8
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APPENDIX - 1
SHEET
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14
OF 79
APPENDIX-1
TYPICAL EMERGENCY LOADS
STEAM TG
500MW
120MW
13kW
15kW
2x5.5kW --11kW
---
13kW
60kW
10kW
---
11kW
---
35kW
37KW
28KW
----
4.4KW
7.5KW
5kW
10kW
2kW
2kW
2kW
Carrier panels
<-----------
<-----------
150watt/ --------->
panel
3watts
--------->
<-----------
10watts
--------->
10
DC emergency lights
<-----------
Approx.
10% of
normal
lighting
--------->
11
55kVA
45KVA
30kVA
210MW
13kW
-----
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APPENDIX - 1
SHEET
15
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APPENDIX-1 (Contd)
TYPICAL EMERGENCY LOADS
500MW
STEAM TG
120MW
210MW
Continuous Loads
Annunciator window (each)
<--------------------3W--------------------------
<--------------------10W-----------------------
<--------------------3W------------------------
<---------------------1kW---------------------
FSSS load
-------------------10kW---------------------
---------------------5W -----------------
NOTES:
1.
The data for 120MW and 210MW units are taken from the designed
data for GIPCL and Bhatinda units. All DC motor loads,
electromagnetic valve loads, FSSS loads, instrumentation & control,
UPS loads, other turbine generator supervisory loads should be as
far as possible ascertained from the manufacturers.
2.
3.
4.
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16
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APPENDIX-2
CELL DATA
RATING AND DESIGNATION
1
Ampere-Hour Rating
The rating assigned to the cell shall be the capacity expressed in
ampere-hours (after correction to 27deg.C) stated by the
manufacturer to be obtainable when the cell is discharged at the 10hour rate (C10) to a final voltage of 1.85 voltage.
2.
Designation
The cell shall be designated by symbols given below, arranged in the
following sequence :
Type of Positive
Plate
(See 2.1)
Ah Rating
of Cell
(See 2.2)
Type of
Container
(See 2.3)
Notes:
1.
2.
2.1
The positive plates shall be designated by the letter 'T' for tubular
and 'P' for plante.
2.2
2.3
DC SYSTEM
SECTION:
APPENDIX-2
SHEET
17
OF 79
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APPENDIX-2 (Contd)
CELL DATA
Capacities and Dimensions of
Tubular Cells
----------------------------------------------------------------------------------------------Capacity at
Maximum Overall Dimensions
10-Hour Rate ---------------------------------------------------------------------Length
Width
Height
(1)
(2)
(3)
(4)
Ah
mm
mm
mm
--------------------------------------------------------------------------------------------20
105
170
365
40
105
170
365
60
140
170
365
80
165
190
365
100
190
190
450
120
190
190
450
150
190
190
550
200
265
215
550
300
320
215
550
400
380
215
550
500
390
235
550
600
390
235
715
800
515
235
715
1000
515
300
750
1500
450
400
865
2000
500
450
865
2500
650
450
865
4000
900
480
1240
5000
900
480
1240
6000
900
500
1240
7000
1100
500
1240
8000
1100
500
1240
--------------------------------------------------------------------------------------------NOTES :
1.
2.
DC SYSTEM
SECTION:
APPENDIX-2
SHEET
19
OF 79
3.
For capacities not covered in this table, the cell dimensions shall
not exceed the dimensions of the cell of next higher size covered
by this table.
SOURCE : IS 1651 - 1991
APPENDIX - 2 (Contd)
Standard Discharge Performance Cells (Tubular)
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APPENDIX - 2 (Contd)
CELL DATA
Capacities at 27deg.C at various rates of discharge
Type II High Discharge Performance (HDP) Cells (Tubular)
------------------------------------------------------------------------------------------------Period of Capacity Ratio :
Capacity
Final Remarks
Discharge Ah capacity (CT)
Rating Factor Cell
Hours (T) divided by the 10hr (KT) = (1/2) Voltage
Rated capacity (C10)
(Volts)
(1)
(2)
(3)
(4)
------------------------------------------------------------------------------------------------1/60 (1 min)
0.022
0.76 1.75 } M/s Chloride
1/2 (30 min)
0.368
1.36 1.75 } India
1
0.60
0.488
0.392
1.67
2.05
2.55
1.75
1.80 } M/s Chloride
1.85 } India
0.738
0.714
0.597
2.71
2.80
3.35
1.78
1.80 } M/s Chloride
1.85 } India
0.811
3.77
1.80
0.862
4.13
1.81
0.90
5.55
1.82
0.93
6.45
1.83
0.951
7.361 1.83
0.971
8.239 1.84
0.988
9.109 1.84
10
1.0
10.0 1.85
---------------------------------------------------------------------------------------------Source : IS 1651-1991 & Capacity Rating curves from M/s Chloride India.
NOTE : The above data is applicable for plante cells also. The capacities for
Type-I HDP cells are same as above for discharge rates of 3 hour, 5
hour and 10 hours (ISS does not specify capacities at other
discharge rates for Type-I cells).
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APPENDIX-2
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APPENDIX - 2 (Contd)
CELL DATA
Capacities and Dimensions: Plante Cells
----------------------------------------------------------------------------------Capacity at
Maximum
Overall
Dimensions
10-Hour Rate ---------------------------------------------------------Length
Width
Height
(1)
(2)
(3)
(4)
Ah
mm
mm
mm
----------------------------------------------------------------------------------20
130
140
225
40
205
140
225
60
205
140
225
80
175
235
370
100
175
235
370
120
175
235
370
150
175
235
370
200
210
235
370
300
290
235
370
400
365
235
370
500
375
310
625
600
375
310
625
800
375
335
625
1000
385
375
635
1500
520
390
635
2000
650
390
635
2500
785
405
130
4000
1160
405
130
5000
1350
515
650
----------------------------------------------------------------------------------NOTES :
1.
2.
For capacities not covered in this table, the cell dimensions shall
not exceed the dimensions of the cell of next higher size covered
by this table.
Source : IS 1652-1995
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APPENDIX-3
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L6 = 84 A
L5 = 186 A
L3 = 46A
L2 = 30A
L1 = 13 A
SECTION-1
60
120
600
SECTION-2
SECTION-3
SECTION - 4
DURATION ( MIN )
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SHEET
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25
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APPENDIX - 3
SAMPLE CALCULATION FOR SIZING OF A THERMAL POWER
STATION 220V UNIT BATTERY (210 MW)
LOAD TABULATION
Sl.
no
Load description
Qty.
Rating
Watts
1 min
1 hr.
I.
UNIT LOADS
1.
a.
6.6 kV CBs
34
300
10,200
b.
415 V CBs
250
1,750
2.
Turb. Generator
a.
E.O.P.
13,000
32,500*
13,000
b.
11,000
27,500*
c.
28,000
70,000*
28,000
d.
Others
2,000
2,000
Steam generator
10,000
2hrs.
10 hrs.
11,000
10,000
DC CSP (includes
FSSS, mill panel)
4.
4,000
10,000
5.
7,500
18,750 *
7,500
6.
Emergency lighting
5000
7.
Indicating lamps
400
1#
8.
Annunciation
windows
10
9.
Auxiliary relays
LS
LS
1000
400
100
50
600 (200
nos @ 3W
each )
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26
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II
STATION LOADS
1.
Tripping loads
6.6 kV CBs
70
300
21,000
415 V CBs
12
250
3,000
2.
Indicating lamps
500
1 #
3.
PA system
LS
LS
4.
Auxiliary relays
LS
LS
500
2,000
300
(100 nos
@3W
each )
TOTAL AMPS
894
232
116
13
*
#
2.0
SIZING CALCULATION
2.1
2.2
Sl.
no
Duration
0 10 hrs.
2850 W
13A
1 min. - 2 hrs.
(11000+7500) =18500W
84A
0 2 hrs.
30A
1 min. - 1 hr.
(28000+13000) = 41000 W
186A
0 1 hr.
(51000 -(13000+28000))
=10000 W
46A
0 - 1 min.
196680 W
894A
In Watts
in Amperes
NOTE: These loads are arrived at taking care to see that loads are not
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repeated under the same time duration , for example in (0-1hr) load
duration the load would be (51000-(13000+28000))=10000,
(13000+28000) being subtracted from the total load as the same is
already considered under (1minute -1hr )load.
2.3
The cell sizing data that will be useful in filling out the cell sizing work
sheet is derived from the duty cycle diagram and tabulated as below :
Cell sizing data
--------------------------------------------------------------------------------period
Loads
Total Amperes
Duration (min)
---------------------------------------------------------------------------------
2.4
1.
L1+L2+L3+L4
983
1
2.
L1+L2+L3+L5+L6
359
59
3.
L1+L2+L6
127
60
4.
L1
13
480
-------------------------------------------------------------------------------Capacity rating factors (KT) are derived from the table for HDP, Type
II tubular lead acid cells enclosed in Appendix-2. (These can be read
from the curves enclosed in Appendix-2 also).
2.5
Sh.29 &30 shows the way in which the cell sizing work sheet and the
KT rating factor would be used to size the battery for the duty cycle
indicated.
2.6
Design margin
Considered as 1.0 since the loads for 210 MW thermal power plant
are well established.
2.7
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NOTES :
1.
2.
If plante cells are being sized, the data on capacities for Type II HDP
cells enclosed in Appendix-2 can be used sizing procedure also
remains same except the value of 'K' in formula for temperature
correction factor (Refer cl.5.2.3).
3.
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APPENDIX-3
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29
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Project :
Date :
Lowest Expected
Electrolyte Temp : 17oC
(1)
Period
(2)
Load
(Ampe
res)
Minimum 1 Min.:1.75V DC
Cell Voltage : Others: 1.85V DC
Cell Chloride
Mfg. : India
Cell Tubular
Type : HDP, Type-II Sized By : RRN
(3)
(4)
(5)
(6)
(7)
Change in
Load
(Amperes)
Duration
of Period
(minutes)
Time to
End of
Section
(minutes)
Capacity
at T Min.
rate
K Factor
(KT)
Pos Values
Neg.Value
LOAD DATA :
A1= 983 A,
M1= 1 Min;
A2 = 359 A,
A3= 127 A,
M3= 60 Min;
A4 = 13 A,
A5= A,
M5= Min; A6 = A, M6 = Min.
M2 = 59 Min.
M4 = 480 Min.
0.76
Total
747
747
2.55
2.55
Sub Total
Total
2507
3.35
3.35
2.55
Sub Total
Total
3293
10
10
9.1
8.2
Sub Total
Total
9830
2507
916
3293
611
9830
544
Sub Total
Total
***
***
1591
1591
***
2090
592
2682
***
6240
2111
935
9286
***
***
Section - 6: IF LOAD CYCLE HAS MORE THAN 5 LOAD PERIODS, CONTINUE FURTHER IN SIMILAR MANNER.
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T=M+R=
Section - 8:
Maximum Section Size = 916
Section - 9:
Random Section Size = -
Section - 10:
Temperature Correction Factor = 1.043
Section - 11:
Design margin = 1.0
Section - 12:
Aging Factor = 1.25
Section - 13:
Uncorrected size = (8) + (9)= 916+ - = 916
Section - 14:
All capacity required = (13) x (10) x (11) x (12) = 916 x 1.043 x 1.0 x 1.25 = 1193 AH
Section - 15:
When AH capacity required is larger than the nearest standard cell, the next larger size cell is required.
Section - 16:
Therefore AH capacity of the cell = 1200 AH
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APPENDIX-4
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32
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Project :
Date :
Lowest Expected
Minimum
Electrolyte Temp : oC Cell Voltage :
Cell
Cell
Mfg. :
Type :
Sized By :
(1)
(2)
(3)
(4)
(5)
(6)
Period
Load
(Amperes)
Change in
Load
(Amperes)
Duration
of Period
(minutes)
Time to
End of
Section
(minutes)
Capacity
at T Min.
rate
K Factor
(KT)
(7)
Required Section Size or
(3)x(6B) = Rated AH
Pos Values
Neg.Value
LOAD DATA :
A1=
A3=
A5=
A,
A,
A,
M1=
M3=
M5=
Min;
Min;
Min;
A2 =
A4 =
A6 =
A,
A,
A,
M2 =
M4 =
M6 =
Min.
Min.
Min.
Total
***
***
Sub Total
Total
***
Sub Total
Total
***
Sub Total
Total
***
Sub Total
Total
***
A2=
A3=
A4=
A5=
A2-A1=
A3-A2=
A4-A3=
A5-A4=
M2=
M3=
M4=
M5=
T=M2+...+M5=
T=M3+...+M5=
T=M4+M5=
T=M5=
Sec.-5
ISSUE
R3
FORM NO. 120 R1
DC SYSTEM
SECTION:
APPENDIX-4
SHEET
33
OF 79
Section - 6: IF LOAD CYCLE HAS MORE THAN 5 LOAD PERIODS, CONTINUE FURTHER IN SIMILAR MANNER.
T=M+R=
Section - 8:
Maximum Section Size =
Section - 9:
Random Section Size =
Section - 10:
Temperature Correction Factor =
Section - 11:
Design margin =
Section - 12:
Aging Factor =
Section - 13:
Uncorrected size = (8) + (9)=
Section - 14:
All capacity required = (13) x (10) x (11) x (12)
Section - 15:
When AH capacity required is larger than the nearest standard cell, the next larger size cell is required.
Section - 16:
Therefore AH capacity of the cell = AH
ISSUE
R3
FORM NO. 120 R1
DC SYSTEM
SECTION:
FACING SHEET
SHEET
34
OF 79
PART-B
NICAD BATTERY
ISSUE
R3
FORM NO. 120 R1
DC SYSTEM
SECTION:
WRITEUP
SHEET
35
OF 79
1.0
SCOPE
This section outlines the Ni-Cd alkaline station storage battery
performance characteristics, usage and sizing.
2.0
2.1
2.2
The cells are further classified as H,M,L and X type based on the
discharge performance of individual designs. The plate type, and the
number of such plates employed in a cell indicate the cell type and
determine its discharge characteristics.
2.3
3.0
PERFORMANCE CHARACTERISTICS
3.1
3.2
SECTION:
WRITEUP
SHEET
DC SYSTEM
36
OF 79
3.3
3.4
3.5
3.6
3.7
EFFECT OF TEMPERATURE
Battery optimum performance is based on cell electrolyte temperature
maintained at 20-25C. For temperatures below 20C a loss of about
0.5% of rated capacity per C is expected for Ni-Cd battery. No
increase in capacity is to be considered above 20C. The derating
curves enclosed in Appendix-1 can be used for arriving at the
derating factors appropriate to the lowest expected electrolyte
temperature for the individual installation.
Example:
Cell Type
Cell end Volt
Discharge time
Min. Ambient temperature
Lowest expected electrolyte temp.
: KPM100P
: 1.1 V
: 30 mins
: 0C
: 0+10C ( Ref. Clause 5.2.3
ISSUE
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FORM NO. 120 R1
SECTION:
WRITEUP
SHEET
DC SYSTEM
37
OF 79
3.7.1
3.8
CHARGING REQUIREMENTS
To fully charge, a cell will require an Ah input, from the charger to the
battery, of 160% of the capacity. For example a 100Ah cell requires
160 Ah to fully charge it from a fully discharged state. If the charger
can supply 20A then the time for charging will be 160/20 i.e. 8 hours.
3.9
Cell Data :
Type-L
Type-M
Type-H
a) D C internal resistance,
ohms
10xC5
15xC5
25xC5
3.10
3.11
4.0
4.1
ISSUE
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FORM NO. 120 R1