Battery Sizing Calculation

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M/s. JSW 2250mm Hot Strip Mill
Sizing Calculation
Battery and Battery charger
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Contract
INABB/PA-MME/ AC
INABB/PA-MME/ MJS
Design Criteria
Battery and battery charger
Sizing Calculations
Project
Date:2008.02.18
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M/s. JSW Steel Limited

3.5mtpa 2250mm width HSM#2
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TEMPLATE: 7AN0.DOT; FILENAME: BATTERY SIZING CALCULATION; PRINTDATE: 2/19/2008 7:13:00 PM; SAVEDATE: 2/19/2008 7:13:00 PM SKELETON 3BYN200812E4035
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CONTENTS
Doc. kind
Title
General ...................................................................................................................................... 3
Applicable standards................................................................................................................ 3
General Description: ................................................................................................................ 3
Design Considerations.............................................................................................................. 3
Design basis ............................................................................................................................... 4
Load Details .............................................................................................................................. 4
Design Criteria
Sizing Calculations
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TEMPLAPE: 7AN0.DOT; FILENAME: BATTERY SIZING CALCULATION; PRINTDATE: 2/19/2008 7:13:00 PM; SAVEDATE: 2/19/2008 7:13:00 PM SKELETON 3BYN200812E4035
REV - OWNER INAUT/AMME
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General
The purpose of this document is to provide project specific design criteria for the sizing of the
battery and battery charger.
Applicable standards
IEC60896
Stationary lead acid batteries.
IEEE 485-1983
IEEE recommended practice for sizing lead acid batteries
3 General Description:
In this project all the DC loads shall be fed from 110V battery. The calculation for sizing of the
battery and its charger are shown below. The battery is to supply the DC power requirements during
the following conditions:
a) Load on dc system exceeds the maximum output of the battery charger.
b) Output of the battery charger is interrupted.
c) AC power is lost
Some Definitions:
Temperature derating factor: The operating temperature affects the available capacity of a cell.
The standard temperature for stating cell capacity is 25 deg C. If the lowest expected electrolyte
temperature is below standard a cell large enough to have the required capacity is selected. The
capacity deration factor for the same is known as temperature factor.
Design Margin: As a prudent design we are to provide a capacity margin to allow for unforeseen
addition to the DC system.
Aging Factor: The performance of a lead acid battery is relatively stable throughout most of its
life, but begins to decline at the later stage of its life. To ensure that the battery is capable of
meeting its design loads throughout its service life, the batterys rated capacity should be at least
125% of the load expected at the end of its service life ie an ageing factor of 1.25 is considered.
4 Design Considerations
1. The battery is sizing is done for a duty cycle of 30 minutes.
2. The calculated battery size is to be corrected for design margin, aging compensation and
minimum temperature.
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3. The batteries considered are sealed, maintenance free lead acid type with a 10 hour discharge
rate i.e. C10 batteries.
4. 2Volt batteries with an end cell voltage of 1.75volts are considered.
5. K factors corresponding to 1.75 end cell voltage and temperature correction factor for the
lowest ambient temperature are taken from Exide batteries ltd. (power stack series of VRLA
batteries).
6. This calculation is done for battery nominal voltage of 110V D.C., which is the control supply
voltage.
5 Design basis
1. The loads on the battery are as follows:
a) 6.6kV HT switchboard control supply
b) 33kV HT switchboard Control supply
2. It is required to be identified which all loads are instantaneous and which all loads are
continuous. For example an 'on' lamp in a breaker feeder is a continuous load, while a tripping
relay is an instantaneous load coming in at the time of a trip.
3. A design margin of 5% may be allowed for unforeseen additions or future expansion as well as
for below optimum operating conditions.
4. Battery capacity is referred to at a nominal temperature of 20 deg.celcius. (The factors given by
Exide are at 20deg C). A temperature correction factor for the lowest temperature is considered
while determing the AH capacity of the battery.
5. The momentary load such as coil closing /tripping shall be considered as one minute loads.
6. The voltage at the load terminals shall never be outside +10% and 15% of the nominal voltage.
7. The spare transformer and motor feeders are not considered in the feeder list for the total load
calculation of the battery
8. An overall diversity of 50% is considered for the total load calculations. (Simultaneous
operation of all the breakers does not happen together. In case of any fault condition in an
outgoing the respective breaker shall trip or the incomer shall trip in case of any bus fault)
6 Load Details
The individual loads supplied by battery during the duty cycle maybe classified as continuous or
non-continuous. Non-continuous loads lasting for 1 minute or less are designated as momentary
loads.
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Continuous loads: Loads, which are energized through out the duty cycle, are known as continuous
loads. These loads are normally carried by the battery charger and are initiated at the inception of
the duty cycle.
Some of the continuous loads are: Indication lamps, (ON, TCH etc)., continuously energized coils ,
annunciator loads etc.
Momentary loads: These are non continuous loads which can occur one or more times during the
duty cycle but are of short duration ie less than 1 minute. Although the momentary loads may exist
for only a fraction of second, it is common practice to consider that each load will last for one full
minute because the battery voltage drop after several seconds.
Some of the typical momentary loads are: switchgear coil operations (trip and close), etc.
The AH capacity of the battery is calculated as:
AH =AH1* K1 * K2 * K3
Where K1 = Ageing Factor
K2 = Design Margin
K3= Temperature correction factor (For the lowest temperature of 10deg C)
AH1 = max of (Ap A (p-1) )*K

Where p=1 to S (S is the section of the duty cycle being analyzed).
K = Capacity rating Factor which is obtained from the Manufacturer for a given end cell voltage and
discharge capacity.(annexure-A)
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The load cycle of the battery is as indicated below.
A3 A2
A2 - A1
A1
A3
A2
M1
M2
M3
S1
S2
S3
Time in Minutes
In this project,
S1 = 1 minute, S2=28 minutes & S3=1 minute
M1 = S1-0= S1 =1 minute, M2= S2-S1 = 28 minutes & M3=S3-S2 =1 minute
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7.1 Load list

The power consumption of the various connected loads in watts is listed below.
MV Switchboard
ITEM
1
Power consumption in watts
VCB
1.1 6.6kV CLOSING COIL
180
1.2 6.6kV TRIP COIL
180
1.3 33kV CLOSING COIL
310
1.4 33kV TRIP COIL
310
RELAYS:
2.1 REF542plus relay
40
2.2 REM543 Relay
<50
2.3 Master trip relay RXPQ8
2.4 PSU14
65
2.5 Aux relay for trafo faults
2.6 Antipumping RXME
2.7 Aux relay for AC and DC fail
INDICATING LAMP (LED)
3.1 RED (ON)
3.2 GREEN(OFF)
3.3 AMBER(TRIP)
3.4 YELLOW (Y Phase)
3.5 WHITE (DC Fail,TCH)
3.6 BLUE(SPRING CHRG)
Annunciator per window
1.5
The load in amperes is calculated as:

A= W/ V*0.85
Where
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V =110Volts, W = Power consumption in Watts.

An efficiency of 0.85 is considered, as the powers indicated above are the output power.(The
power consumed by the device is also considered)
7.1
DC Load Details
ITEM
TOTAL
TOTAL
TOTAL
TOTAL
Total
SYSTEM
VOLTAGE
110.00
110.00
110.00
110.00
of 33kV switchgear
of 6.6KV switchgear sec 1 & 2
7.2
0-1 MIN.
30.66
44.91
45.09
42.72
163.38
LOAD (AMP)
1-29 MIN. 29-30 MIN.
4.55
30.73
20.29
45.31
20.47
45.32
19.14
42.98
64.44
164.34
CONTINUOUS
4.55
21.05
21.03
19.67
66.30
Battery Capacity
The load changes seen by the battery is calculated as below:

The K factors used in the below calculation are the factors given by Exide at 20 deg C.
LOAD DETAILS
PERIOD
LOAD
TOTAL AMPS
DURATION (MINUTES)
1
2
3
A1
A2
A3
163.38
64.44
164.34
M1=1
M2=28
M3=1
Sl.No.
PERIOD
CHANGE IN
LOAD AMPS
DURATION
OF LOAD
AMPS
TIME TO
END OF
SEC.
K
FACTO
R TO
1.75EC
V
REQD.
CAPACIT
Y (AH) AT
1.75ECV
(a)
MIN.
MIN.
(b)
(a) X (b)
SECTION-A
1
A1-A0=
163.38
M1=1
T=M1=1
0.74
120.9045
SECTION-B
1
A1-A0=
163.38
A2-A1=
-98.95
M1=1
T=M1+M2
=29
T=M2
=28
1.35
220.5691
1.34
-132.5891
M2=28
TOTAL
SECTION-C
1
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87.9800
A1-A0=
163.38
Design Criteria
Sizing Calculations
M1=1
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T=M1+M2
+M3 = 30
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A2-A1=
-98.95
A3-A2=
99.91
M2=28
M2=28
T=M2+M3
=29
T=M3
=1
1.35
-133.5785
0.74
73.9313
TOTAL
162.5557
Highest capacity from the above three sections AH1, AH1 & AH1 is AH1
Ie AH1 = AH1=162.55 AH
The final AH capacity is calculated after multiplying by the ageing factor, design margin and
temperature correction factor.
Ie AH =AH1* K1 * K2 * K3
K1 Ageing Factor =1.25
K2 Design margin =1.05
Temperature correction factor (For the lowest temperature of 10deg C)=
K3=1/(1+0.006(1 - 2)
Where
1 =Lowest temperature seen by battery i.e. 10 deg C.
2 = Temperature at which the K factors are selected.
The K factors given by Exide are at an temperature of 20 deg. Hence 2 = 20 deg C
=1/(1+0.006*(10-20))
=1.06
Required AH Capacity of the Battery = 162.55*1.25*1.05*1.06
=227 AH
A battery capacity of 240AH has been selected. The battery cells of 2 Volts are selected
with an end cell voltage of 1.75V.
The No of cells shall be 55 Nos.
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Float Charger Capacity

ICC =Continuous DC load current = 66.3 Amps
A design margin of 5 % is considered for unforeseen continues loads.
A trickle charging current Icc is as recommended by the manufacturer.(Usually 2%)
ITC = ICC *0.02
The total required capacity of the float charger shall be = ICC *1.05 + ITC
= 66.3 *1.05 + 66.3 *0.02

= 71 Amps
A float charger of 75 Amps had been selected.
Boost Charge capacity:

The boost charger shall be equal to maximum allowable battery charging current (generally
14% of the battery ampereage or the float charger capacity, which ever is higher.
As the float charger capacity is higher than the 14% battery charging current the boost charge
capacity is selected as 75 Amps
The offered combination for the JSW Hot strip Mill is dual float cum boost chargers rated
of 75 Amps with a 110V, 240AH, lead acid SMF batteries.( 55 cells of 2 Volts )
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Battery Sizing Calculation

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We reserve all rights in this document and in the information contained therein.

M/s. JSW 2250mm Hot Strip Mill

M/s. JSW Steel Limited

Rev. ind. Sheet

General Description: ................................................................................................................ 3

Design basis ............................................................................................................................... 4

Load Details .............................................................................................................................. 4

M/s. JSW Steel Limited

Rev. ind. Sheet

Stationary lead acid batteries.

IEEE recommended practice for sizing lead acid batteries

M/s. JSW Steel Limited

Rev. ind. Sheet

M/s. JSW Steel Limited

Rev. ind. Sheet

AH1 = max of (Ap A (p-1) )*K

M/s. JSW Steel Limited

Rev. ind. Sheet

The load cycle of the battery is as indicated below.

M/s. JSW Steel Limited

Rev. ind. Sheet

7.1 Load list

Power consumption in watts

1.1 6.6kV CLOSING COIL

1.2 6.6kV TRIP COIL

1.3 33kV CLOSING COIL

1.4 33kV TRIP COIL

2.1 REF542plus relay

2.2 REM543 Relay

2.3 Master trip relay RXPQ8

2.5 Aux relay for trafo faults

2.6 Antipumping RXME

2.7 Aux relay for AC and DC fail

INDICATING LAMP (LED)

3.1 RED (ON)

3.4 YELLOW (Y Phase)

3.5 WHITE (DC Fail,TCH)

3.6 BLUE(SPRING CHRG)

Annunciator per window

The load in amperes is calculated as:

M/s. JSW Steel Limited

Rev. ind. Sheet

V =110Volts, W = Power consumption in Watts.

The load changes seen by the battery is calculated as below:

M/s. JSW Steel Limited

Rev. ind. Sheet

M/s. JSW Steel Limited

Rev. ind. Sheet

Float Charger Capacity

= 66.3 *1.05 + 66.3 *0.02

Boost Charge capacity:

M/s. JSW Steel Limited

Rev. ind. Sheet

M/s. JSW Steel Limited

Rev. ind. Sheet

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= 66.3 1.05 + 66.3 0.02