PROJECT NAME- Construction of 400/220kV AIS Substation at

Fatehgarh –IV and 400kV Bay extn. at Fatehgarh-3

Document Title: 48V BATTERY SIZING CALCULATION For
400/220kV AIS Substation at Fatehgarh –IV
Document
CG-APRAAVA-330-EL-209 Rev.: 0 Page 1 of 9
No. :

CONTENTS

Sl DESCRIPTION PAGE NO
1 INTRODUCTION 1-2
2 CALCULATION FOR NUMBER OF CELLS 3
3 DESIGN CRITERIA FOR BATTERY CHARGER SIZING 4
4 REFERENCES 4
5 ASSUMPTIONS 4
6 SIZING CALCULATION 4
i) 220V DC LOAD DETAILS 5
ii) LOAD SUMMARY 6
iii) LOAD CYCLE TABLE & GRAPH 7
iv) AH sizing calculation of Battery & Battery charger 8
v) BATTERY CHARGER SIZING 9
7 ANNEXURES
1. LOAD DETAILS FOR CRP Annex 2.1
3. CORRECTION FACTOR Annex 1.5
1 INTRODUCTION:
DC Power Supply is the most reliable source of power supply for control, protection interlock
& annunciation requirements both during the AC power failure and in normal operating
conditions.

This document is intended to size the 48V Lead Acid Battery required for Communication
/FOTE at 400/220kV Switchyard ( 765 kv extn) Fategarh_IV pooling substation
The battery is sized in accordance with the IEEE 485 (2010)

One set of 48V DC Power supply will consist of One no. of 100% rated battery along with One
no. of 100% rated Float cum boost charger to charge above battery.

2 DESIGN CRITERIA FOR BATTERY SIZING:

Battery Sizing is based on the following criteria as per Guidelines, Project Specification & IEEE
Std. 485 (2010)

The dischage capacity of the battery shall be sufficient to supply loads during
a discharge time of 10 [Link] battery shall be capable of following conditions:

i Considering all FOTE/PLCC panels in service .There is no momentary load but the total load is
continueous.

ii Supplying of normal standing load (DC Continuous load) for the full discharge period

Section Number Duration Load description

DC continuous load +
Section - 1 0 - 1 min.
Intermittent Relay Load
Section - 2 1 - 60 min. DC continuous load + Emergency Load

Section - 3 60 - 599 DC continuous load

Section - 4 599 - 600 min. DC continuous load + Emergency Load if any

vi The end cell voltage (ECV) has been considered as 1.85 Volts/cell

vii Design Margin Considered 10% as per IEEE-485-2010, Cl. No. 6.2.2.

viii Ageing Factor considered 1.25 as per IEEE-485-2010, Cl. No. 6.2.3.

The sections have been considered as per the duty cycles of the loads as mentioned against
them in loads distribution table.

A design margin of 10% is considered (for design contingencies) on the

final calculated Ampere Hour Capacity & the next higher battery size available
from the vendor list is selected.
Page 1
 GENERAL DESIGN INPUTS

i Project contract documents

ii Standard used is IEEE 485-2020

ASSUMPTIONS

i Standard electrolyte temp. considered for battery = 27 deg C .

CALCULATION

RESULT

2300 Ah Battery with the end cell voltage of 1.85V/cell, having total such 24
nos. of cell is selected as Battery Set to feed DC load.

Page 2
3.0 CALCULATION FOR NUMBER OF CELLS

A INPUT DATA

i Nominal System (Battery) voltage = 48 V

ii Allowable System Voltage Percentage = ± 10 %

iii Maximum Allowable System Voltage = 52.8 V

``
iv Minimum Allowable System Voltage = 43.2 V

v Float charing voltage/cell Vfloat = 2.2 V

vi End cell voltage Vend = 1.85 V

B CALCULATION

Maximum Allowable System Voltage

No. of Cells (Ncells) required =
Cell Voltage required for Float Charging

52.8
=
2.2

Minimum No. of Cells required = 24

No. of Cells Selected = 24

Minimum Battery Voltage at the end of the load cycle = No. of Cells X End Cell Voltage

= 24X1.85V

= 44 V

Which is in between of maximum & minimum allowable system voltage

Hence the determination of No of cells required as 24 is justified.

Page 3
4 DESIGN CRITERIA FOR BATTERY CHARGER SIZING

i Under normal float charge conditions (with AC supply available), the battery charger will cater
to the continuous load of the DC system plus trickle charging of the battery.

ii The batteries may require boost charging from time to time, dependending upon service
conditions & other external forces. Under boost charge condition the charger shall be capable
of supplying full boost charge requirement, taking care not to exceed the maximum
permissible battery voltage & simultaneously cater to the continuous load requirement of the
DC system.

The higher of the two ratings (float charging condition & boost charging condition calculated
as above) will be considered for rating the charger

5 REFERENCES

i Project Specification

ii IEEE - 485 (2020)

iii P-SLD

iv Load list of PLCC and FOTE ( communication devices )

6 ASSUMPTIONS

i
DC Load details are considered as per Manufacturer details for FOTE,PLCC.

7 SIZING CALCULATIONS

i 48V DC Load details

ii Load Cycle table & graph

iii AH sizing calculation of Battery & Battery charger

Page 4
 48V DC LOAD DETAILS_FATEGARH_IV SUBSTATION
CONSIDERED LOAD OF 400kV,220kV communication SYSTEM
UNIT TOTAL CONTINOUS
LOAD (A) LOAD (A) REMARKS
[Link] DESCRIPTION DUTY CYCLE Qty. LOAD LOAD LOADS (A)
W W 0 - 1 MIN 1 - 60 MINS 60 - 600 MINS
(VA=VA1*Q
Q (VA1) (A=VA/220) (A=VA/220)
)
1 PLCC FOTE and other devices Continous 1 6978 6978 145.4 145.4 145.4
2 PLCC FOTE and other devices intermittend 1 0 0 0.0 0.0 0.0
3 other ( emergency ) Continous 1 100 100 2.1 2.1 2.1

4 other intermittend 1 0 0 0 0 0
As per
Annexure - 2.1

SUB TOTAL = 147.5 147.5 147.5

loads taken for duty clycle operations

all the loads are continueous type as per the Ann 2.1, total loads of FOTE ,PLCC etc given by mfr as 6978
Watts which is considered . There is no momentary load however 100Watt load is considered as
emergency load assuming that any external device is required to be connected. which gives 100/48=2.1A .

Page 5
 [Link] - LOAD SUMMARY
Load Duration
[Link] DESCRIPTION
0 - 1 MIN 1 - 60 MINS 60 - 600 MINS REMARKS

1 FOTE PLCC All cont load 145.4 145.4 145.4

2 LOAD OF EQUIPMENTS emergency 2.1 2.1 2.1

3 other 0.0 0.0 0.0

TOTAL LOAD IN AMPS 147.5 147.5 147.5

Page 6
 7iii - LOAD CYCLE TABLE & GRAPH

Load Cycle Table

LOAD CYCLE DURATION LOAD DESCRIPTION LOAD (A)

L1 0 - 1 min 147.5 A

L2 1 - 60 min DC continuous load + Emergency Load 147.5 A

L3 60 - 600 min Continuous load+Emergency 147.5 A

time current
0 0
0 0
1 147.5
1 147.5
60 147.5
60 147.5
600 147.5
600 0.0
0.0
0.0
0.0
0

BATTERY LOAD CYCLE

147.5
160
147.5
140

120 16.08.07
CURRENT IN AMP

100

80

60

40

20
TIME IN MIN 0.0
0
0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640

Page 7
 [Link] - AH SIZING CALCULATION OF 220V BATTERY & BATTERY CHARGER

A CELL SIZING CALCULATIONS

1 . NOMINAL SYSTEM VOLTAGE (VN) = 48 V

2 . HIGHEST SYSTEM VOLTAGE (VH) = 52.8 V

3 . LOWEST SYSTEM VOLTAGE (VL) = 43.2 V

4 . END CELL VOLTAGE = 1.85 Volts

5 . NO OF CELLS = 24 Cells

B AH Sizing of Battery
Load Details:

L1 = 147.5 A

L2 = 147.5 A

L3 = 147.5 A

Duration of Capacity Rating Factor Required Section Size (AH)

Period Load (A) Change in Load Period Time to end of section at
(Mins) t Min. rate (F) Positive values Negative values
Section 1: First Period only (if L2>L1, go to section - 2)
1 L1 = 147.5 L1 - 0 = 147.5 M1 = 1 t = M1 = 1 0.50 73.7
Section 1 73.7
Section 2: First Two Periods only (if L3>L2, go to section - 3)
277.2
1 L1 = 147.5 L1 - 0 = 147.5 M1 = 1 t = M1+M2 = 60 1.88

2 L2 = 147.5 L2 - L1 = 0 M2 = 59 t = M2 = 59 1.88 0
277.2 0
Section 3: First Three Periods only (if L4>L3, go to section - 4)
1628.0
1 L1 = 147.5 L1 - 0 = 147.5 M1 = 1 t = M1+M2 + M3 = 600 11.04

2 L2 = 147.5 L2 - L1 = 0 M2 = 59 t = M2 + M3 = 599 11.04 0.0

3 L3 = 147.5 L3 - L2 = 0 M3 = 540 t = M3 = 540 10.04 0.0

Section 3
1628.0

Maximum Section Size = 1628.0 AH

Design Margin = 1.1

Ageing Factor = 1.25

Temperature correction factor for 27 = 1.00 (IEEE 485 PAGE 14 of 36)

Required Size = Maximum Section Size x Design Margin x Ageing factor x [Link] factor

= 1628.0 x 1.1 x 1.25 x 1.00

Battery Size Calculated = 2238 AH

Nearest Standard Sizing As per Availability = 2300 AH

Battery Size Selected = 2300 AH

Thus, for 100% load, one number of 2300 Ah battery With ECV of 1.85 is selected

page 8 of 9
 7.v. DETERMINATION OF BATTERY CHARGER

A. INPUT DATA:

Continuous DC load Lc = 147.46 A

Ampere Hours discharged from Battery AH = 2300 AH

Time to recharge the battery T = 10 Hours (approximate)

CALCULATION:
B. BATTERY CHARGER SIZING FOR 120 AH BATTERY FOR FLOAT CHARGING

i. Recommended Battery Size = 2300 AH

ii. DC Nominal Voltage = 48 V

Battery Charger current rating is the sum of the continuous load current & the float charging current of
the battery

Battery Charger Rating = Continous Load Current + Float Charging Current

Continous Load Current = 147.46 A

Float Charging Current = 2.00 mA per Hour (to prevent the Self disCharge of
the battery)
= 0.02 x AH
= 0.16 A
Battery Charger Rating = 147.62 A

Design Margin = 10 %

Battery Charger Float Rating = 162.39 A

Battery Charger rating considering the Float Charging requirement is 220V ,175 A.

B. BATTERY CHARGER SIZING FOR 600 AH BATTERY FOR BOOST CHARGING

i DC Nominal Voltage = 48 V
Battery Charger current rating is the sum of the continuous load current & the boost charging
current of the battery

Boost Charging Current = 15% of Ah battery

= 345.00 AH
Battery Charger Rating = Continous Load Current + Boost Charging Current

= 492.46 A
Design Margin = 10 %

Battery Charger Boost Rating = 541.710 A

Battery Charger considering the boost charging requirement is 220V ,550A.

Since the boost charging rating is higher than the float charging rating,
Hence, as per calculation battery charger rating is 48V, 550/175A.( Boost /Float)

Page 9