DESIGN BASIS REPORT FOR DC SYSTEM

3 08.10.2012 GENERALLY REVISED AN -Sd- SS -Sd- RRC -Sd-

REVISED AS PER APGENCO COMMENTS,

2 24.12.2011 REF:CPP/631/KTPP-II/DBR for DC MS -Sd- SS -Sd- DJS -Sd-
SYSTEM/D.No.250/11. dt:24th Oct 2011.
REVISED AS PER APGENCO COMMENTS,
1 12.08.2011 REF:CPP/631/KTPP-II/DC MS -Sd- SS -Sd- DJS -Sd-
SYSTEM/D.No.165/11. dt:25th July 2011.
REVISED AS PER APGENCO & DESEIN
COMMENTS,
1A 08.07.2011 MS -Sd- SS -Sd- DJS -Sd-
REF:D-0298/VC4100B/HYD/323 dt:05th July
2011.
0 17.02.2011 FOR APPROVAL SS/MS -Sd- DJS -Sd- ADK -Sd-

0A 07.02.2011 PRELIMINARY ISSUE SS/MS -Sd- DJS -Sd- SCV -Sd-

REV NAME SIGN NAME SIGN NAME SIGN

DATE DESCRIPTION OF REVISION
NO. PREPARED BY CHECKED BY APPROVED BY

PROJECT KAKATIYA THERMAL POWER PROJECT, STAGE‐II, UNIT # 2 (1X600MW)

ANDHRA  PRADESH  POWER  GENERATION 

OWNER
CORPORATION LIMITED, HYDERABAD
 

OWNER’S
CONSULTANT DESEIN PRIVATE LIMITED, NEWDELHI 
 

TECPRO SYSTEMS LIMITED 
BOP  
CONSORTIUM
GAMMON  INDIA 
VA TECH WABAG LIMITED 
  LIMITED 
 
BOP
CONSORTIUM FICHTNER CONSULTING ENGINEERS (INDIA) PVT. LTD., CHENNAI 
CONSULTANT

EBOP
CONTRACTOR G.E.T. POWER PVT. LTD., CHENNAI‐96 
 
DOC. NO   0894‐FCE‐EBOP‐DO‐E‐065  REV NO. 3 
ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

TABLE OF CONTENTS

1.0.0 INTENT ...................................................................................................................... 3

2.0.0 REFERENCE DOCUMENTS ..................................................................................... 3
3.0.0 DESIGN CRITERIA .................................................................................................... 4
4.0.0 SPECIFIC REQUIREMENTS ..................................................................................... 6
5.0.0 DESIGN DATA ......................................................................................................... 11
6.0.0 CALCULATION ........................................................................................................ 12
7.0.0 CONCLUSION ......................................................................................................... 13
8.0.0 ANNEXURES ........................................................................................................... 14

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

1.0.0 INTENT

1.1.0 The Kakathiya Thermal power plant project phase-II proposed at Chelpur village,
Gunpur Mandal, in Warangal District, Andhra Pradesh, by Andhra Pradesh Power
Generation Corporation Limited comprises 1 X 600 MW Stage II, Unit#2 generating
unit. The existing Power plant under phase –I is installed with 1x500MW generating
unit. 220V DC Power supply is envisaged for control, protection, interlock and
annunciation requirements of the power station during normal running of the plant, as
well as for a safe shut down in case of total power supply failure. This document
covers the design basis for Unit, Station and CHP/AHP 220V DC system.

2.0.0 REFERENCE DOCUMENTS

 Key Single Line Diagram for Auxiliary :Drg.No.0894-FCE-EBOP-DR-E-001

Power Distribution
 Design Basis Report for Electrical :Doc.No.0894-FCE-EBOP-DO-E-001
System
 BHEL Documents
a) List of feeder loads for Steam Turbine, :Doc.No.4-18000-88-151
Generator, Condenser and Auxiliaries
b) Requirement of Electrical power :Doc.No.3-97-591-93507
c) Schedule of LT Motors :Doc.No.3-97-599-93548
d) Electrical load list for each BFP drive :Doc.No.HY-DG-330-139-0108
Turbine
e) PEM Electrical load list
f) EDN-Requirement of Electrical power supply to be arranged by customer
 Tender Specification for Engineering :Doc.No.# PCT-B-02/2009
Procurement & Construction of Balance of Plant
 Technical Data & Capacity Calculation Curves of ‘EXIDE Battery’.
 IEEE: 485 - IEEE recommended practice for sizing large lead storage batteries for
generating stations and substation.
 IS: 1652 - Stationary Cells and Batteries, Lead-Acid Type (With Plante Positive
Plates) – Specification
 IS: 266 - Sulphuric Acid.
 IS: 1069 - Water for storage batteries.

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

3.0.0 DESIGN CRITERIA

3.1.0 SCOPE

(a) One (1) 100 % rated Plante type Lead-Acid battery with associated float and float
cum boost charger and DC switchboard for the unit.

(b) One (1) 100% rated Plante type battery with associated float and float cum boost
charger and DC switchboard for station (common) loads.

(c) One (1) stand by float cum boost charger for above batteries.

(d) One (1) 100% Plante type battery with 2 sets of 100% rated float cum boost
chargers and DC switchboard for catering to the DC loads of coal handling and ash
handling systems.

3.2.0 One battery for unit services and one battery for station services are proposed. Each
of the unit and station batteries are sized to cater for DC load of one unit as well as
common station DC load, so that each battery will serve as standby to the other.

3.3.0 To cater the outage of any unit/station chargers, one common standby float and boost
charger shall be provided for station and unit DC systems with manual selection
arrangement.

3.4.0 Temperature correction factor is considered for minimum electrolyte temperature of

4ºC above minimum site ambient temperature considering the fact that the electrolyte
temperature varies because of charge discharge cycle and also the inside room
temperature is normally higher than the ambient temperature i.e.,4+22.3 i.e.26.3ºC.

3.5.0 As per Table-2 of IS: 1652, the corrected capacity of battery towards electrolyte
temperature is calculated as follows:

Capacity at 27°C = Ct + (Ct x R x (27-t)) / 100

Where,
Ct = Observed Capacity at t°C
R = Variation factor which is 0.9 for C10 rating.
t = Average electrolyte temperature, which is 26.3°C

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

3.6.0 Design Margin of 10% over estimated loads is considered for sizing the batteries.

3.7.0 Ageing factor is taken as 1, as per Battery manufacturer’s catalogues and

recommendation.

3.8.0 220V DC system voltage at the load end is to be maintained within -20% to +10% of
nominal voltage.

3.9.0 End cell voltage at the end of each discharge cycle is considered as 1.85 V/cell.

3.10.0 The following loads are considered:

(a) Momentary Load (For duration up to 1 minute)

(i) Tripping load of 11kV, 3.3kV & 415V breakers.
(ii) Starting current of all automatically started DC drives.
(iii) Solenoid valves
(iv) In rush current of excitation system
(v) Spring Charging Motor

(b) Emergency Load (For 4 hours duration)

(i) Running currents of essential DC motors.
(ii) Emergency lighting

(c) Continuous Load (For 10 hours duration)

(i) Indicating lamps on switchgear and control & relay panels.
(ii) Control room emergency lighting.
(iii) Auxiliary relays.

3.11.0 Each float charger is sized to cater the continuous load with 25% margin, trickle-
charge current of battery and full load current of largest rated DC motor. The other
DC drives and DC lighting loads are not considered since corresponding AC
auxiliaries are ‘ON’ at that time.

3.12.0 Each Boost charger is sized to cater to boost charge one battery bank within 10
hours. Constant current mode of charging will be adopted.

3.13.0 Under normal conditions, the float charger connected to the DC switchboard and
battery shall cater to the continuous load of DC system plus trickle charging current of
battery, In case of AC supply failure in the plant/to charger, battery shall meet the DC
load. After restoration of AC supply, the fully / partly discharged battery shall be

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

charged by boost charger and float charger continue to feed DC load. During this
period, if AC fails, boost charger shall feed the load via tap cell of battery.

3.14.0 For the battery in CHP/AHP the DC loads that come under CHP and AHP are
considered.

4.0.0 SPECIFIC REQUIREMENTS

4.1.0 Batteries

a) The batteries shall be Plante type capable of high discharge performance as per
Table-2 of IS: 1652 for Plante cells.

b) The battery shall be closed top or sealed in type. Open type cells are not
acceptable.

c) All the accessories required for testing and maintenance shall be supplied with
the batteries along with electrolyte for first filling. These shall also include + 3
Volts DC voltmeter with suitable leads for measuring cell voltage and hydrometer
for measuring specific gravity of electrolyte in steps of 0.005.

4.2.0 Battery Charger

a) The float and float cum boost charger offered shall be static type with silicon
controlled rectifiers and diodes, complete with resistor/capacitor network for surge
protection, connected in three phase full wave bridge circuit.

b) Charger shall have provision for manual control if the auto mode fails. Load
limiting features shall be provided. The charger shall be designed for adequate
short time over load to take care of the starting of the largest DC motor / testing of
lamps, etc. with other DC loads connected to bus.

c) The chargers shall be provided with automatic voltage regulation in float mode
and automatic constant current regulation in boost mode.

d) The charger shall essentially comprise the following items:

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

 One (1) moving coil DC voltmeter and ammeter of size 96 x 96 mm of suitable

range for float and boost chargers. Necessary shunts for local and remoter
metering shall be provided.

 One (1) moving coil centre zero ammeter, with shunt, size 96x96mm to read
discharge / charge current of the battery.

e) Fault indicating lamps shall be provided on the charger cubicle and following
initiating contacts shall be provided for remote alarm for each of the float and
boost chargers. The alarms shall be provided on the CRT in the common control
room.
(i) Main AC failure
(ii) AC input fuse blown
(iii) DC output fuse blown
(iv) U/V and current limit protection
(v) Over voltage protection
(vi) Over current protection
(vii) Filter condenser fuse blown
(viii) Rectifier fuse blown

In addition to the above, any additional indication/alarms considered necessary

during the detailed engineering shall also be provided.

f) The above said alarms shall be provide on each battery charger and one a
common alarm contact shall be generated on each charger for remote
alarm/indication in the control room.
g) The charger shall be natural air-cooled and no external fans shall be provided to
dissipate the heat developed within the panel.

4.3.0 DC Switchboards

a) For feeding the 220 V DC loads, following DC switchboards shall be provided

 220 V DC unit switchboard
 220 V DC Station switchboard
 220 V DC Coal/Ash handling switchboard

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

b) The switchboards shall be provided with suitably rated incomers, required

quantity and type of outgoing feeders for the axillaries, control supplies to various
panels/systems in accordance with the number of 220 V DC supplies enumerated
in the respective equipment specification for each load. In addition, the following
feeders shall be provided in each switchboard.

 10% or minimum of two nos. feeders of each type which ever is higher
shall be provided as spare in each bus section and rating as spare. The
same is the minimum quantity at the time of handling over the plant. Any
additional quantity required for increase/adjustment during detailed
engineering stage shall also be duly considered.
 1 No. Switchboard for 240 V 1 phase space heating modules.
 1 No. Alarm module for common alarm of outgoing feeder fault.

c) Current Ratings

The short circuit current rating of the switchboard shall be 25KA/Sec minimum
considering the contribution from charger and battery with 5% margin. Calculation
shall be furnished in this regard and higher short circuit rating shall be provided if
required.

The continuous current rating of the bus bars, incomers, ties for 220 V DC
switchboards shall be the maximum DC load (excluding the momentary load) on
the bus due to any operating condition, when unit system additionally feeds
station system or vice-versa plus 20% margin rounded off to the next higher
standard rating.

d) Specific Requirements

The constructional features of all DC switchboards shall comply with the

requirements of 415 V AC switchgears in this specification as applicable.

Positive and negative bus bars in the DC switchgear shall be completely

segregated from each other by partitions. Switches to be provided in DCDB must
be DC rotary type.

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

4.4.0 Module details

a) Incomer

The incomer modules shall be switch fuse unit/breaker controlled. Each incomer
shall be provided with:

(i) Ammeter & voltmeter

(ii) Earth fault relay.
(iii) Under voltage relay with time
(iv) Indicating lamps for ON, OFF, EARTH FAULT, UNDER VOLTAGE
conditions.
(v) Current and voltage transducers for remote indication.
(vi) Necessary hardware an circuitry for fault alarm, lamp test and alarm rest.

b) Outgoing switch fuse feeders and tie feeders / bus coupler

(i) These feeders shall be provided with suitably rated switch-fuses on positive
and negative sides with feeder on and fault indicating lamps.
(ii) The feeders rated 200 Amps and above shall be provided with a shunt and
ammeter.

c) Motor Modules

(iii) For DC motors, starters shall be preferably housed within the DC

switchboard. However, the resistors can be separately mounted in boxes /
panels, which may be located adjacent to DC switchboard.
(i) The motor modules shall be provided with :
a) Switch, fuses, air break contactors.
b) Thermal overload relays.
c) Starting resistors with associated timers.
d) ON, OFF, FAULT indicating lamps.
e) Necessary auxiliary contractors for fault alarm circuit.
f) 240 V space heating circuit.
g) ON, OFF PBs for testing purposes.

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

h) One No. shunt with ammeter(local) indication and 1 No. transducer i.e.,
signal converted with mV/4 to 20mA for ammeter indication.
i) Appropriate circuitry for receiving the ON, OFF commands from remote
panels/systems, interlocks, etc.
j) MCB for space heating circuit.

d) Space Heating Module

(i) 240 V, 1 space heating module shall be provided with incoming side switch
fuse, suitably rated 415/240 V cast resin type transformer (expected heating
loads of the switchgear and the connected motors + 30 % margin), secondary
fuse, supply indicating lamp and connection to space heating buses. The 415
V power supply for these modules shall be obtained from the unit service
switchgear.

e) Alarm Module

(i) Alarm module for outgoing feeder faults shall be provided with switch fuse,
alarm accept, reset PBs, `supply ON’ lamp, `fault detect’ lamp, hooter,
necessary auxiliary contactors, control circuit for detecting, annunciating,
accepting, resetting the fault in any module of the particular bus section.
Contacts from this module for common feeder fault and its own module supply
failure shall be provided and used for annunciation in DCS.

(ii) Alarm module for incomers / bus coupler faults shall be similar to the above
except that it shall work on 240 V AC supply.

f) Control Room Alarms / Indications / SER points

(a) Following indications/alarms shall be available in the control room CRTs.

(i) Incomer, bus coupler, ties - ON & OFF
(ii) Incomer current
(iii) Alarm module supply failed
(iv) Outgoing feeder fault
(v) Incomer alarm supply fail
(vi) Bus under voltage

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

(vii) Bus earth fault

(viii) Bus voltage
(b) For the annunciation in control desk, alarms of a particular bus shall be grouped
as one window. The requirement of contacts to SER shall be duly considered and
provided.

4.5.0 Necessary equipment for charge/discharge of batteries shall be supplied. This

equipment shall be mounted on a movable trolley.

4.6.0 Battery room shall be well ventilated and exhaust fans shall be provided as per
relevant standards

5.0.0 DESIGN DATA

Float Charger/Float Cum Boost Charger,

1. Type of Charger
SCR controlled
DC System Voltage
2. 220V DC -20% to +10%
including % variation
3. System Earthing Unearthed
Mean Minimum ambient
4. 22.3 deg C
temperature
Maximum time for boost
5. 10 hours.
charging the battery
6. Battery Type Plante
2.23 V per cell (as per Exide catalogue,
7. Float Charging Voltage
Annexure 5, sheet 1 of 5)
8. Boost Charging Voltage 2.75 V per cell. (max.)

9. Minimum End cell voltage 1.85 V per cell

a) ±1% of set DC voltage with ±10%
Voltage stabilization for
10. variation in supply voltage.
constant voltage regulator
b) ±5% during transient.
DC current adjusting for
11. 30% to 100% of Max. boost charger current
boost charger
Current stabilization for
12. constant current regulator ± 2%
for boost charger

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

Min. permissible p.f. at

13. 0.8
rated continuous load
Permissible ripple content
14. 1 % Max.
at rated continuous load

6.0.0 CALCULATION

6.1.0 Battery Sizing Calculation

Minimum system voltage = 80% of 220V

= 176 V
Maximum system voltage = 110% of 220V
= 242 V

Considering 3% voltage drop in the cable i.e, .6.6 V

Minimum allowable battery voltage = Minimum system voltage + Cable drop

= 176 + 6.6
= 182.6 V
Minimum allowable battery voltage
Min No. of cells required = --------------------------------------------------
End cell voltage for charging
182.6
= ---------- = 98.7 Cells (Say 99 Cells)
1.85
Maximum system voltage
Max. No. of cells required = --------------------------------------
Float charging voltage
242
Max. No. of cells required = ---------- = 108 cells
2.23
No. of cells selected = 108

Maximum battery voltage = No. of cells x Float charging voltage

= 108 x 2.23
= 240.84V

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

Calculated maximum battery voltage is less than the maximum allowable system
voltage of 242 V. hence, dropper diodes are not required. Though 108 cells will be put
in battery stack, supply of cells shall be 110 cells as a standard practice.
Ampere-hour calculation for Battery is calculated as per IEEE-485 and is enclosed in
Annexure – 3.

6.2.0 Charger Sizing Calculation

Float and Float Cum Boost Charger sizing calculation & DCDB sizing is enclosed in
Annexure-4

7.0.0 CONCLUSION

7.1.0 Unit & Station DC System

Type of Battery : Plante Lead Acid

End Cell Voltage : 1.85 V
Selected battery AH rating : 2 x 2250AH =4500AH
No of Batteries : 1 set of 4500AH for Unit & 1 set of 4500AH for
Station
No. of cells : 110 (for each battery)
DC system voltage : 220 V
Float Charger rating : 500A
Float cum Boost charger rating: 550A
3
Standby Float Cum Boost : 550A
Charger rating
DCDB : 1250A

7.2.0 CHP/AHP DC System

Type of Battery : Plante Lead Acid

End Cell Voltage : 1.85 V
Selected battery AH rating : 200AH
No. of cells : 110
DC system voltage : 220 V
Float cum Boost charger rating: 50A
Charger rating
DCDB : 63A

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ANDHRA PRADESH POWER GENERATION CORPORATION LIMITED DESIGN BASIS REPORT FOR
KAKATIYA THERMAL POWER PROJECT DC SYSTEM
STAGE-II, UNIT # 2 (1X600 MW)

8.0.0 ANNEXURES

Annexure - 1 : 220V DC Load Data for Plante Lead Acid Battery.

Annexure - 2 : Load Cycle for 220V DC Plante Lead Acid Battery.
Annexure - 3 : Sizing Calculation for 220V DC Plante Lead Acid Battery.
Annexure - 4 : Sizing Calculation for 220V DC Charger & DCDB.
Annexure - 5 : Cuts from ‘Exide’ catalogue.
Annexure - 6 : List of Emergency Unit loads

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