REPORT OF

SUBSTATION
BATTERY BANK
DESIGN,
Pallekele.
Revision-01

AMITHI POWER CONSULTANTS (PVT) LTD,

NO. 1080/9,
ATIGALAMAWATHA,
RAJAGIRIYA,
SRI LANKA

FEBRUARY 2013

Contents
EXECUTIVE SUMMERY ........................................................................................................................... 3
1

CODES AND STANDARDS .............................................................................................................. 4

110V BATTERY BANK ..................................................................................................................... 4

2.1

2.1.1

Site conditions ....................................................................................................................... 4

2.1.2

Power source data ................................................................................................................. 4

2.1.3

Back-up time ......................................................................................................................... 4

2.1.4

Battery characteristic............................................................................................................. 4

2.1.5

Formula for calculation of battery size ................................................................................. 4

2.2

DESIGN PARAMETERS AND ASSUMPTION ........................................................................ 4

CALCULATION .......................................................................................................................... 5

2.2.1

110V DC Load profile .......................................................................................................... 5

2.2.2

Battery duty cycle diagram ................................................................................................... 5

2.2.3

Cell sizing ............................................................................................................................. 6

2.2.4

Battery charger sizing ........................................................................................................... 6

48V BATTERY BANK ....................................................................................................................... 7

3.1

DESIGN PARAMETERS AND ASSUMPTION ........................................................................ 7

3.1.1

Site conditions ....................................................................................................................... 7

3.1.2

Power source data ................................................................................................................. 7

3.1.3

Back-up time ......................................................................................................................... 7

3.1.4

Battery characteristic............................................................................................................. 7

3.1.5

Formula for calculation of battery size ................................................................................. 7

3.2

CALCULATION .......................................................................................................................... 8

3.2.1

48V DC Load profile ............................................................................................................ 8

3.2.2

Battery duty cycle diagram ................................................................................................... 8

3.2.3

Cell sizing ............................................................................................................................. 9

3.2.4

Battery charger sizing ........................................................................................................... 9

Attachments 1.Loads Description ............................................................................................................... 10

Attachments 2.Battery Sizing Worksheet for 110V Battery Bank.............................................................. 11
Attachments 3. Capacity Derating Factors(Kt) for Ni-Cd Battery [110V] ................................................. 12
Attachments 4. Manufacture Catalog for Ni-Cd Battery ............................................................................ 13
Attachments 5. Battery Sizing Worksheet for 48V Battery Bank............................................................... 14
Attachments 6. Capacity DeratingFactors(Kt) for Ni-Cd Battery [48V] .................................................... 15
Attachments 7. Manufacture Catalog for Ni-Cd Battery ............................................................................ 16

EXECUTIVE SUMMERY
At the request of Mr.RuupeshSrivastava,Manager-Civil of Siemens Ltd, Amithi Power
Consultants Pvt Ltd has designed substation battery bank system for the grid substation of
Pallekele.
This document contents the descriptive report of the design.

Certified by:

..
DG Rienzie Fernando
B.Sc. Eng, C.Eng, MIE (SL),
Managing Director,
Amithi Power Consultants (Pvt) Limited.
14/02/2013

1 CODES AND STANDARDS

IEEE 946-1992: Recommended Practice for the Design of Safety-Related DC
Auxiliary Power Systems for Generating Stations
IEEE 1115-2000: Recommended Practice for Sizing Nickel-Cadmium Batteries for Stationary
Applications

2 110V BATTERY BANK

2.1 DESIGN PARAMETERS AND ASSUMPTION
2.1.1 Site conditions
Ambient temperature

: 28Maximum
:25Design
:25Minimum

2.1.2 Power source data

1) Rated input voltage rating: 400V, 3 Phase, 50Hz AC
2) Rated output voltage: 110V DC (Operating range: 99V-126V DC)
2.1.3 Back-up time
Back-up time of DC 110V system is limited as 8 hours.
2.1.4 Battery characteristic
Rated Capacity
: 335Ah
Rated voltage
: 1.2V/cell
Float charging voltage
: 1.40V/cell
End voltage
: 1.1V/cell
Number of cell
: 90cell
Battery re-charging time
: 8 hours
2.1.5 Formula for calculation of battery size
Battery size = US TC DM AF [Ah]
Where
US : Uncorrected size
TC : Temperature correction factor (=1.0 )
(applied standard temperature for rating cell capacity at 25C)
DM : Design margin (= 10%)
AF : Aging factor (=1.2)

2.2 CALCULATION
2.2.1 110V DC Load profile
Duration 132kV
33kV
Miscellaneous Total
(A)
(sec)
(A)
(A)
(A)
0-1
21.56
30.08
23.38
75.02
1_4
11.32
15.15
23.38
49.85
4-28796
2.52
1.15
23.38
27.05
2879628797
21.56
30.08
23.38
75.02
2879728800
11.32
15.15
23.38
49.85

Refer the attachment 1 for load Description

2.2.2 Battery duty cycle diagram

2.2.3 Cell sizing

From the attached battery sizing work sheet (Refer to the Attachment No.1), uncorrected size
(US) is 246.48Ah
And the corrected battery capacity is,
Battery size

= US DM AF [Ah]
= 246.69 1.1 1.2
= 325.64

Therefore, the selected battery capacity is 335 [Ah].

2.2.4 Battery charger sizing
Charger shall supply the DC power to DC load and battery charging. So we consider continuous
load current and [Ah] of battery discharge rating.
Battery charger I = IL+
=27.05+
=73.11A
=73.11*1.5
=109.67A
The battery charger has designed to provide 150% of the total DC circuit load.
Therefore, the selected battery charger capacity is 110 [A]
where,
I : charger rated output [A]
IL: continuous DC load [A]
1.1 : constant that compensate for the battery losses
Q : ampere-hours discharged from the battery
T : time to re-charge the battery to approximately 95% of capacity

3 48V BATTERY BANK

3.1 DESIGN PARAMETERS AND ASSUMPTION
3.1.1 Site conditions
Ambient temperature

: 28 Maximum
: 25 Design
: 25 Minimum

3.1.2 Power source data

1) Rated input voltage rating: 400V, 3 Phase, 50Hz AC
2) Rated output voltage: 48V DC (Operating range: 43.2V-54.6V DC)
3.1.3 Back-up time
Back-up time of DC 48V system is limited as 10 hours.
3.1.4 Battery characteristic
Rated Capacity
: 270Ah
Rated voltage
: 1.2V/cell
Float charging voltage
: 1.40V/cell
End voltage
: 1.1V/cell
Number of cell
:39cell
Battery re-charging time
: 8 hours
3.1.5 Formula for calculation of battery size
Battery size = US TC DM AF [Ah]
Where
US : Uncorrected size
TC : Temperature correction factor (=1.0 )
(applied standard temperature for rating cell capacity at 25C)
DM : Design margin (= 10%)
AF : Aging factor (=1.2)

3.2 CALCULATION
3.2.1 48V DC Load profile
Type
Communication & SCADA load

3.2.2 Battery duty cycle diagram

Continuous Intermediate
Load [A]
Loads [A]
20
0

3.2.3 Cell sizing

From the attached battery sizing work sheet (Refer to the Attachment No.1), uncorrected size
(US) is 184.43Ah
And the corrected battery capacity is,
Battery size

= US DM AF [Ah]
= 200 1.1 1.2
= 264

Therefore, the selected battery capacity is 270 [Ah].

3.2.4 Battery charger sizing
Charger shall supply the DC power to DC load and battery charging. So we consider continuous
load current and [Ah] of battery discharge rating.
Battery charger I = IL+
=20+
=57.125A
=57.125*1.5
=85.69A
The battery charger has designed to provide 150% of the total DC circuit load.
Therefore, the selected battery charger capacity is 90 [A]
where,
I

: charger rated output [A]

IL : continuous DC load [A]

1.1 : constant that compensate for the battery losses
Q : ampere-hours discharged from the battery
T : time to re-charge the battery to approximately 95% of capacity

Attachments 1.Loads Description

Discription

Duty Cycle

132kV DC Incoming
Transform
Load
er
Bus bar
protection
Bus PT
Bus Coupler
Cont.Total
Inter.tripp
ing for all
1st
tripping
coil for all
2nd
tripping
for all
Closing
coil of the
breaker
Bus
Coupler
Inter.Tota
l
33KV DC
Out going
Load
line
Transform
er
Generator
feeder
Bus
Section
Cont.Total
Inter.tripp
ing for all
1st
tripping
coil for all
2nd
tripping
for all
Closing
coil of the
breakerr
Bus
Section
Inter.Tota
l
Miscellan RTCC &
eous Load OLTC
132
Contactor,
Relay
33
Contactor,
Relay
Inverter
Emergenc
y Ligting
Emergenc
Metering
Cont.Total

Unit
values

Quantity

Duration(sec)
VA

Load A

38.6

77.2

0.70

0.70

2879728800
4-28796 28796-28797
0.70
0.70
0.70
0.70

38.6

77.2

0.70

0.70

0.70

0.70

0.70

0.70

2
2
1

10.5
45
11.75

21
90
11.75
277.15

0.19
0.82
0.11
2.52

0.19
0.82
0.11
2.52

0.19
0.82
0.11
2.52

0.19
0.82
0.11
2.52

0.19
0.82
0.11
2.52

0.19
0.82
0.11
2.52

I 0-1Sec

28

0.25

0.25

0.25

I 0-1Sec

242

968

8.8

8.8

8.8

I 0-1Sec

242

968

8.8

8.8

8.8

I 0-4Sec

242

968

8.8

131

131

1.19

1.19

3063

27.85

19.04
21.56

8.8
11.32

0
2.52

19.04
21.56

8.8
11.32

0-1

1_4

c
c
c

8.8

8.8
1.19

54

0.49

0.65

0.65

0.65

0.65

0.65

15

30

0.27

0.27

0.27

0.27

0.27

0.27

18

0.16

0.08

0.08

0.08

0.08

0.08

16.3

16.3
118.3

0.15
1.08

0.15
1.15

0.15
1.15

0.15
1.15

0.15
1.15

0.15
1.15

I 0-1Sec

10

8.65

86.5 0.78636364

0.865

0.865

I 0-1Sec

10

140

1400 12.7272727

14

14

I 0-1Sec

10

140

1400 12.7272727

14

14

I 0-4Sec

10

140

1400 12.7272727

14

14

0.064

0.064

0.064

4293.5 39.0318182

28.929
30.08

14
15.15

0
1.15

28.929
30.08

14
15.15

72

144

1.31

1.31

1.31

1.31

1.31

1.31

28

112

1.02

1.02

1.02

1.02

1.02

1.02

c
c

10

28

280 2.54545455
1000
9.09

2.8
9.09

2.8
9.09

2.8
9.09

2.8
9.09

2.8
9.09

1000

9.09

9.09

9.09

9.09

9.09

9.09

0.07

0.07

0.07

0.07

0.07

0.07

2544

23.124

23.38

23.38

23.38

23.38

23.38

Attachments 2.Battery Sizing Worksheet for 110V Battery Bank

IEEE 1115-2000 Recommended Practice for Sizing Nickel-Cadmium Batteries for Stationary
Applications
Lowest Expected
Electrolyte Temp. : 25

(1)

Period

Minimun Cell
Voltage :
1.1V

(2)

Cell Mfg : HBL

Load
(Amperes)

KPL335P

(4)
Duration of Period
(Minutes)

(3)
Change in load (Amperes)

(6)
Capacity rating
factor at
t Min Rate
K Factor (Kt)

(5)
Time to End of Section
(Minutes)

(7)
Temp Derating
factor for t
Min(Tt)

(8)

Required
Section
Size Rated Amp Hrs
(3) X (6) X (7) = Rated Amps

Pos Values

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

1
A1=
75.02
A1-0=

75.02

M1=

0.017

T1=M1=

0.579

1.00

Neg Values

43.4

Sec 1 total
Section 2 -First Two Periods Only - If A3 is greater than A2 , go to Section 3.
1
A1=
A1-0=
0
2

A2=

A2-A1=

43.4

M1=

T1=M1+M2=

0.00

1.00

0.0

0.0

M2=

T2=M2=

0.00

1.00

0.0

0.0

Sec Sub Tot

2 Total

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

1
A1=
A1-0=
0.00

M1=

A2=

A2-A1=

M2=

A3=

A3-A2=

M3=

0.02 T1=M1+M2+M3=
479.87 T2=M2+M3=
0.02 T3=M3=

0.0

479.900

8.092

1.00

479.883

8.091

1.00

0.017

0.579

1.00

0.0
0.0
0.0

Sec Sub Tot

3 Total
Section 4 -First Four Periods Only - If A5 is greater than A4 , go to Section 5.
1
A1=
A1-0=
75.02
2
A2=
A2-A1=
49.85
3
A3=
A3-A2=
27.05
4
A4=
A4-A3=
75.02

0.0

75

M1=

0.017

T1=M1+...+M4=

480.000

8.092

-25

M2=

0.050

T2=M2+M3+M4=

479.983

8.092

-23

M3=

479.866

T3=M3+M4=

479.933

8.091

48

M4=

0.067

T4=M4=

0.067

0.579

-204
-184
28
635

M1=

T1=M1+...+M5=

480.00

0.00

1.00

A2=

A2-A1=

M2=

298

T2=M2+...+M5=

479.00

0.00

1.00

A3=

A3-A2=

M3=

T3=M3+M4+M5=

181.00

0.00

1.00

A4=

A4-A3=

M4=

179

T4=M4+M5=

180.00

0.00

1.00

A5=

A5-A4=

M5=

T5=M5=

1.00

0.58

1.00

0.00
0.00
0.00
0.00
0.00

M1=

T1=M1+...+M6=

480.00

0.00

1.00

A2=

A2-A1=

M2=

298

T2=M2+...+M6=

479.00

0.00

1.00

A3=

A3-A2=

M3=

T3=M3+M4+M5+M6=

181.00

0.00

1.00

A4=

A4-A3=

M4=

179

T4=M4+M5+M6=

180.00

0.00

1.00

A5=

A5-A4=

M5=

T5=M5+M6=

1.00

0.00

1.00

A6=

A6-A5=

M6=

T6=M6

Random Equipment Load Only (If needed)

R
AR=

AR-0=

MR

Maximum Section Size (9) ________ + Random Section Size (10) ________ = Uncorrected Size (US) (11) ________
US (12) ________ x Design Margin (13) 1.
x Aging Factor (14) 1.
= (15) ________
When the cell size (15) is greater than a standard cell size, the next larger cell is required.
Required cell size (16) ________ Ampere Hours. Therefore cell (17) ________ is required.
Maximum Section Size (9)
Random Section Size (10)
Uncorrected Size (US) (11)

246.69
246.69

US (12)
Design Margin (13)
Aging Factor (14)
With factors(15)
Required capacity(16)
Available size(17)

246.69
1.1
1.2
325.6352
325.6352
335

T=MR=

0.00
0.00

0.00
0.00
0.00
0.00
0.00

1.00

Sec Sub Tot

5 Total

-388
247

0.00

Sec Sub Tot

5 Total

Section 6 -First Five Periods Only - If A6 is greater than A5 , go to Section 6.

1
A1=
A1-0=

0.0
0.0

607

Sec Sub Tot

4 Toal

Section 5 -First Five Periods Only - If A6 is greater than A5 , go to Section 6.

1
A1=
A1-0=

0.0
0.0

0.00

0.00
0.00

Attachments 3. Capacity DeratingFactors(Kt) for Ni-Cd Battery [110V]

Battery Type

KPL335P

Capacity =

Discharge Time t (min)

Time T1

Time T2

0.067
479.933
479.983
480.000

0.017
300
300
480

0.083
480
480
0

335
Amphers for Amphers
time T1
for time T2
583
577
63.7
41.4
63.7
41.4
41.4
0

Factor Kt1
fot T1
0.5746141
5.2590267
5.2590267
8.0917874

Factor Kt2
fot T2
Factor Kt fot T
0.58058925
0.579117977
8.09178744
8.090733023
8.09178744
8.091519901
0
8.09178744

Attachments 4. Manufacture Catalog for Ni-Cd Battery

Attachments 5. Battery Sizing Worksheet for 48V Battery Bank

IEEE 1115-2000 Recommended Practice for Sizing Nickel-Cadmium Batteries for Stationary
Applications
Lowest Expected
(1)

Minimun Cell
Period

(2)

Load
(Amperes)

Cell Mfg : HBL

(3)
(4)
Duration (5)
Change in load (Amperes)
of Period (Minutes)

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

1
A1=
20.00
A1-0=

20.00

M1=

600

to End of Section
(Minutes)

T1=M1=

600

KPL270P
Time (6)
Capacity
(7)
(8)
rating factor at
Temp Derating
Pos Values
t Min Rate
factor for t Min(Tt)
K Factor (Kt)

10.000

1.00

Required
Section
Neg Values

200.0

Sec 1 total
Section 2 -First Two Periods Only - If A3 is greater than A2 , go to Section 3.
1
A1=
A1-0=
2

A2=

A2-A1=

200.0

M1=

T1=M1+M2=

0.00

1.00

0.0

0.0

M2=

T2=M2=

0.00

1.00

0.0

0.0

Sec Sub Tot

2 Total

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

1
A1=
0.27 A1-0=

0.0

0.27

M1=

0.00 T1=M1+M2+M3=

0.00

6.767

1.00

A2=

0.27 A2-A1=

M2=

0.00 T2=M2+M3=

0.00

6.746

1.00

A3=

0.27 A3-A2=

M3=

0.00 T3=M3=

0.00

10.000

1.00

1.8
0.0
0.0

Sec Sub Tot

3 Total
Section 4 -First Four Periods Only - If A5 is greater than A4 , go to Section 5.
1
A1=
A1-0=

0.0
0.0

1.8

0.0
1.8

M1=

T1=M1+...+M4=

A2=

A2-A1=

M2=

T2=M2+M3+M4=

A3=

A3-A2=

M3=

T3=M3+M4=

A4=

A4-A3=

M4=

T4=M4=

Sec Sub Tot

4 Toal

Section 5 -First Five Periods Only - If A6 is greater than A5 , go to Section 6.

1
A1=
0.27000
A1-0=

M1=

T1=M1+...+M5=

0.00

10.38

1.00

A2=

0.27000

A2-A1=

M2=

T2=M2+...+M5=

0.00

10.36

1.00

A3=

0.27000

A3-A2=

M3=

T3=M3+M4+M5=

0.00

4.23

1.00

A4=

0.00000

A4-A3=

-0

M4=

T4=M4+M5=

0.00

4.21

1.00

A5=

0.00000

A5-A4=

M5=

T5=M5=

0.00

10.00

1.00

Sec Sub Tot

5 Total

Random Equipment Load Only (If needed)

R
AR=

AR-0=

MR

T=MR=

Maximum Section Size (9) ________ + Random Section Size (10) ________ = Uncorrected Size (US) (11) ________
US (12) ________ x Design Margin (13) 1.
x Aging Factor (14) 1.
= (15) ________
When the cell size (15) is greater than a standard cell size, the next larger cell is required.
Required cell size (16) ________ Ampere Hours. Therefore cell (17) ________ is required.
Maximum Section Size (9)
Random Section Size (10)
Uncorrected Size (US) (11)

200.00
200.00

US (12)
Design Margin (13)
Aging Factor (14)
With factors(15)
Required capacity(16)
Available size(17)

200.00
1.1
1.2
264
264
270

0
0

0
0

2.80
0.00
0.00
-1.14
0.00
2.80

-1.14
1.67

Attachments 6. Capacity DeratingFactors(Kt) for Ni-Cd Battery [48V]

Battery Type

KPL270P

Discharge Time t (min)

Time T1
600

Capacity =
Time T2
600 -

270
Amphers for Amphers
Factor Kt1 Factor Kt2
time T1
for time T2 fot T1
fot T2
27
10

Factor Kt fot T
10

Attachments 7. Manufacture Catalog for Ni-Cd Battery