UMKC Substation 125 VDC Battery System Sizing

Revision 4

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April 2, 2014

prepared by

UMKC Senior Design (Substation) Group

UMKC Substation 125 VDC Battery System Sizing

Table of Contents

Table of Contents
1.0 2.0 INTRODUCTION .................................................................................................. 1 SYSTEM DESIGN CRITERIA .............................................................................. 2 2.1 Battery Cells.............................................................................................................2 2.2 Assumed Derating Factors .......................................................................................3 LOAD CLASSIFICATIONS .................................................................................. 4 BATTERY SIZING ................................................................................................ 6 4.1 Battery Capacity & Duty Cycle: ..............................................................................6 4.2 Battery Postive Plates ..............................................................................................7 BATTERY CHARGER SIZING............................................................................. 9 CONCLUSION ................................................................................................... 10 REFERENCES ................................................................................................... 11 APPENDIX A...................................................................................................... 12

3.0 4.0

5.0 6.0 7.0 8.0

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TOC-1

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UMKC 125 VDC Battery System Sizing

Introduction

1.0

INTRODUCTION

The substation DC system provides a continuous source of power for operating circuit breakers, protective relaying, SCADA system, and other critical systems. The station battery is a critical piece of equipment on our system. Batteries provide a reliable source of DC power required for switching, relaying and communications. They provide power for the line and transformer protection systems, circuit breakers and other equipment. The batteries are used to provide an emergency source of DC power needed to aid in safe shutdowns and in station restoration. The battery must accommodate the initial switching load during a disturbance and have enough reserve for restoration at some time in the future. Our battery chargers are sized to provide the continuous station load, maintain a fully charged battery and recharge the battery within 24 hours after a discharge. The chargers are not capable of fully handling switching or restoration loads. The battery is used to provide these high current needs. Poor battery system integrity can result in damage to substation and generating facilities.

After reviewing the layout and the one line diagram of the substation the worst case tripping scenario can be: if a 69 kV line should fall on the 138 kV bus, then one would need to evaluate a simultaneous 69 kV line fault and a 138 kV bus fault. As there might be a bus tie breaker failure, then two simultaneous bus faults would occur. As there is backup relaying, it is assumed that both primary and backup relays will pick up. We have been informed not to consider future expansion in our substation design. Emergency lighting will pick up in the first minute of duty cycle and will be on during the 8 hours period.

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UMKC 125 VDC Battery System Sizing

System Design Criteria

2.0 2.1 BATTERY CELLS

SYSTEM DESIGN CRITERIA

The number of cells (ncells) for the battery can be calculated by the following equation where Vmax is the maximum system voltage specified to be 140VDC, and Vcharge is the maximum charge voltage per cell of 2.33VDC.

The number of cells equates to 60; with this value, the minimum cell voltage (Vcell) is 1.75V/cell which is calculated by the following equation where Vmin is the minimum battery voltage specified to be 105V. (V/cell)

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UMKC 125 VDC Battery System Sizing

2.2

ASSUMED DERATING FACTORS

When sizing a battery, various factors used in the calculations account for the lowest possible temperature, the age, and a design margin; these factors are shown in the following table.

Table 2-1

Battery Correction Factors

Multiplying Factor 1.15 1.25 1.10

Correction Factor Temperature (Assuming 55oF is the lowest) Age (Accounts for battery instability 80% of life) Design Margin (Accounts for unexpected future loads)

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UMKC 125 VDC Battery System Sizing

Load Classifications

3.0

LOAD CLASSIFICATIONS
Table 3-1 Load Classifications

Loads Trip coil 1 Trip Coil 2 Close Coil Emergency Lighting MOAB Relays Communications Announciators Intrusion Alarm

Amps 12 12 1.9 1.536 20 2.5 10 0.144 0.8

Table 3-2
Load Trip Coil 1 Trip Coil 2 MOAB Amps 12 12 20

First Minute Loads (Load L1, Time = 1 minute)

Breakers Tripping = L2 Quantity 4 4 1 Total Total Amps 48 48 20 116 Duration (hr) 0.016666667 0.016666667 0.016666667 0.016666667 Amp Hours 0.8 0.8 0.33333333 1.93333333

The continuous load is primarily made up of relay loads and devices to be continuously energized throughout the eight hour interval. The table below shows the continuous current.

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UMKC 125 VDC Battery System Sizing

Load Classifications

Table 3-3
Load Relays Communications Intrusion Alarm Emergency Lighting Annunciator

Continuous Loads (Load L2, Time = 480 minutes)

Steady State Loads = L1 Amps 2.5 10 0.8 1.536 0.144 Quantity 1 1 1 1 1 Total Total Amps 2.5 10 0.8 1.536 0.144 14.98 Duration (hr) 8 8 8 8 8 8 Amp Hours 20 80 6.4 12.288 1.152 119.84

The following table assumes that the transformer fault and failed breaker issues have been resolved and the affected part of the substation can be re-energized. Following the re-energization, its assumed the station AC service issue is resolved and the eight hour period concluded.

Table 3-4

Closing the breakers

Closing Breaker = L4 Load Close Coil Breaker Motor Amps 1.9 43.5 Quantity 4 4 Total Total Amps 7.6 174 7.6 Duration (hr) 0.083333333 0.083333333 0.083333333 Amp Hours 0.63333333 14.5 15.1333333

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UMKC 125 VDC Battery System Sizing

Battery Sizing

4.0 4.1

BATTERY SIZING

BATTERY CAPACITY & DUTY CYCLE:

To calculate the total number of amp-hours required of the battery, the 480 minute time frame can be divided into periods where each one can be expressed as a function equal to the total amperes consumed in that time frame. The integral of these piecewise functions over the entire time frame yields the total amp-hours. The following table represents this.

Total ampere hour is the sum of all the tables on the previous pages.
Total Amp Hours 136.906667

From the previous Table 4-1, a duty cycle can be shown as the following figure.

Figure 4-1

Load Profile

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Battery Sizing

4.2

BATTERY POSTIVE PLATES IEEE Standard 485 goes into detail on how to calculate the number of positive plates

required of the battery. To do this, the load profile shown in Figure 4-1 used in conjunction with the current per positive plate required to bring the batteries voltage to 1.75 per cell in a specified amount of time are required. The latter is provided by the battery manufacturer and is shown in Appendix A. We can calculate the positive number of plates using IEEE method. The spread sheet below will give us the number of positive plates and we can use this formula to find the total number of plates. We look at at the latter provided by the battery manufacturer, and based on that we can understand how much AmpHour this certain battery will produce.

The total number of plates equates to eleven. The Enersys battery EC-11M will be able to supply the substation considering that the rated capacity of the battery is 470Ah, and the required amount should not exceed 136.906Ah
Battery Sizing Spreadsheet Project: 1 2 UMKC Substation 3 Change Load Period (amps) in Load (amps) 4 Duration of Period (min) 5 Time to End of Section (min) 6 Capacity @ T Min. Rate (6A) Amps/Pos (Rt) 7

Required Section Size (3) / (6A)= Positive Plates

Section 1 - First Period Only - If A2 is greater than A1, go to Section 2. 1 A1= 129.44 A10= 129.44 M1= 1 T=M1= 1 126.5 Sec 1 Total Section 2 - First Two Periods Only - If A3 is greater than A2, go to Section 3. 1 2 A1= A2= 129.44 14.98 A10= A2A1= 129.44 -114.46 M1= M2= 1 480 T=M1+M2= T=M2= 240 475 21.5 13.5 Sec 2 Total Section 3 - First Three Periods Only - If A4 is greater than A3, go to Section 4. 1 2 A1= A2= 129.44 14.98 A10= A2A1= 129.44 -114.46 M1= M2= 1 480 T=M1+M2+M3= T=M2+M3= 475 479 13.5 13.5 9.588148148 -8.47851852 6.020465116 -8.47851852 -2.4580534 1.023241107 1.023241107

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UMKC 125 VDC Battery System Sizing

Battery Sizing

A3=

196.58

A3A2=

181.6

M3=

T=M3=

108.25 Sec 3 Total

1.677598152 2.787227782

Section 4 - First Four Periods Only - If A5 is greater than A4, go to Section 5. 1 2 3 4 A1= A2= A3= A4= 129.44 14.98 14.98 196.58 A10= A2A1= A3A2= A4A3= 129.44 -114.46 0 181.6 M1= M2= M3= M4= 1 239 235 5 T=M1+M2+M3+M4= T=M2+M3+M4= T=M3+M4= T=M4= 480 479 240 5 13.5 13.5 21.5 108.25 Sec 4 Total Section 5 - First Five Periods Only - If A6 is greater than A5, go to Section 6. 1 2 3 4 5 A1= A2= A3= A4= A5= 170 25 25 25 A10= A2A1= A3A2= A4A3= A5A4= 170 -145 0 0 -25 M1= M2= M3= M4= M5= 1 239 235 5 T=M1+M2+M3+M4+M5= T=M2+M3+M4+M5= T=M3+M4+M5= T=M4+M5= T=M5= 480 479 240 5 0 Sec 5 Total Section 6 - First Six Periods Only - If A7 is greater than A6, go to Section 7. 1 2 3 4 5 6 A1= A2= A3= A4= A5= A6= 170 0 0 0 0 A10= A2A1= A3A2= A4A3= A5A4= A6A5= 170 -170 0 0 0 0 M1= M2= M3= M4= M5= M6= 1 239 235 5 0 T=M1+M2+M3+M4+M5+M6= T=M2+M3+M4+M5+M6= T=M3+M4+M5+M6= T=M4+M5+M6= T=M5+M6= T=M6= 480 479 240 5 0 0 Sec 6 Total Random Equipment Load Only (if needed) R AR= AR0= 0 2.787228 0 2.787228 x x x = MR= T=MR= Uncorrected Size Temp. Corr. Design Margin Aging Factor Positive Plates Positive Plates (rounded up) total number of Cells 0 2.78722778 1.15 1.1 1.25 4.40730393 5 0 0 0 9.588148148 -8.47851852 0 1.677598152 2.787227782

Maximum Section Size + = Random Section Size (9) Uncorrected Size

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UMKC 125 VDC Battery System Sizing

Battery Charger Sizing

5.0

BATTERY CHARGER SIZING

When sizing the battery charger, the capacity (A) in amps can be found by the following equation where L is the continuous load being 13.44 Amps, C is the ampere hours emergency discharge which is the 470 Ah battery rating of the Enersys (EC-11M), H is the number of hours recharge time assumed to be 24 hours, and the 1.1 constant is an factor accounting for the efficiency of lead acid cells.

The charger capacity is calculated to be 34.98 Amps, and therefore, the next larger size will be provided by Hindle power or equal capable of handling 40Amps will be sufficient for this substation. So, we will use two 40 Amp battery chargers with a transfer switch feeding each charger from the two AC sources.

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UMKC 125 VDC Battery System Sizing

Conclusion

6.0

CONCLUSION

Battery sizing is based on the worst case cenario which can happen in the substation. In our case the worst case scenario is when all 4 breakers trip, and both primary and backup relays will pick up. After classifying the loads, we should make our duty cycle which is a period of 8 hours. Then based on the IEEE method we should find the number of total plates which will give us the Amp Hour capacity that battery manufacturers can provide. From there we can easily find the charger ampacity. For UMKC substation we are going to use 11 plate battery which has the AmpHour capacity of 470, and two chargers with 40 Amperes.

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UMKC 125 VDC Battery System Sizing

References

7.0

REFERENCES

1) IEEE Recommended Practice for Sizing Lead-Acid Batteries for Stationary Applications, IEEE Standard 485-1997 (R2003) 2) Siemens SPS2 SF6 Breaker Nameplate 3) EnerSys Type EC-M Battery Datasheet 5) Schweitzer Website, www.selinc.com 6) Southern State Website Part Number: VM-1-104125 (MOAB electrical characteristics) 7) SEL Inc. Website. (Relays electrical characteristics) 8) Hindle Power Inc. Website. (Battery Charger electrical characteristics)\

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UMKC 125 VDC Battery System Sizing

Appendix A

8.0

APPENDIX A

ENERSYS EC-M BATTERY DISCHARGE CURRENT

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UMKC 125 VDC Battery System Sizing

Appendix A

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