Battery Sizing Calculation KPD 981 Com E4 005 p0

Battery Sizing Calculation:
Volta River Authority, Ghana

161 & 34.5 kV Switchyard at Kumasi (K2BSP)
CLIENT:
VOLTA RIVER AUTHORITY,GHANA
0 Preliminary 09-09-2010 CCK LRP

REV DESCRIPTION DATE PPD BY CHK BY APD BY
KEC INTERNATIONAL LTD.

TITLE :
BATTERY SIZING CALCULATION Pages 16
161 & 34.5 kV SWITCHYARD AT KUMASI (K2BSP)
DOC No. KPD981-COM-E4-005 REV P0
CONTENTS
1. 125V DC BATTERY
1.1 General Page-3
1.2 Standards Page-3
1.3 System Particulars Page-3
1.4 Service Conditions Page-3
1.5 Input Data Page-4
1.6 Battery Sizing Calculations Page-4
1.7 Design Criteria Page-4
1.8 125V DC Load data Page-5
1.9 125 V DC Duty Cycle Determination. Page-6
1.10 125V Battery sizing Page-7
1.11 125V Battery – Float Charger Page-8
1.12 125V Battery – Boost Charger Page-8
1.13 ANNEXTURE Page-10

BATTERY SIZING CALCULATION
DOC No. KPD981-COM-E4-005 Page No. 2 of 16
1.1 General
This Design Brief covers the estimation of DC loads and Battery Sizing
Calculations for the 125V DC Lead Acid Batteries to be provided at Kumasi Second Bulk
Power Supply 161/34.5kV substation in Ghana.
The requirement of this contract is for the supply of one numbers each of 100%
capacity, 125V DC Batteries, considering both the present 161/34.5kV Substation and
future 330 kV substation requirements as per the specification.
1.2 Standards
The following standard shall apply
IEEE 485: Recommended Practice for Sizing Lead-Acid Batteries for Stationary
Applications
1.3. System Particulars
The equipment to this specification shall conform to and satisfy the following system
particulars.
System Voltage-
1.3.1 Nominal Voltage 125V DC / 48V DC
1.3.2 Nominal cell voltage 2.00V/cell
1.3.3 End cell voltage at the of 10 hour Discharge 1.85V/cell
1.3.4 Discharge time 10 Hrs
1.4. Service Condition
The equipment to the specification shall be capable of operation under following

conditions,
1.4.1 Maximum Ambient Temperature : 400C
1.4.2 Minimum Ambient Temperature : -10C
1.4.3 Average Ambient Temperature : +30 0C
1.4.4 Maximum relative humidity : 90 %

1.4.5 Annual average rainfall : 800-1700 mm
1.4.6 Maximum wind velocity : 120 km / hr
1.4.7 Isokeraunic level : 180 days
1.5 Input Data
Manufacturer’s catalogues for all the Protection Devices/Subsystems/Components give the

data on their consumptions in terms of DC loads and this form the basis for load
determination. Wherever data is assumed for the sake of load determination, it is on higher
side and the same has been mentioned.
1.6 Battery Sizing Calculations
Battery sizing calculations is in four steps viz.
Step 1- Design Criteria that is set based on either the specifications or actual conditions
likely to be encountered. In this case specifications are the basis.
Step 2 -Load Determination based on the specifications together with the loads imposed by
the connected devices during their operation for the intended purpose based on the Vendor
data.
Step 3 -Duty Cycle Determination is based on the sequence of incidences.
Step 4 -Battery Sizing Estimation based on the above duty cycle.
1.7 Design Criteria
a) Rating
Battery shall be capable of supplying the entire (present + future) DC load connected to the
main distribution boards.
The DC loads of the substation have been taken into account as specified-
.
b) Standby Period
According to the requirement of the specification, the battery of 100% rated capacity
should be determined for 10 hours standby period, when Charger is out of service; under
specified site environmental condition taking into account the following DC loads.

Load Description
Category Brief Title Brief Description
L1 Continuous Standing Loads All Protection Relays

( 0-10 hours) All Indicators, Alarms, Etc.
L2 Non-continuous Standing Loads Supply Of Emergency Lighting Loads

(0-3 hours) Some part of the annunciations.
L3 Momentary Loads-Abnormal Simultaneous tripping of all 161 kV

During Bus Fault CBs,34.5kV CBs and 415V CBs
( 0-1min)
c) Additional Capacity Allowances
Design Margin = 1.15

Ageing Factor = 1.25
Temp. Correction = 1.04
It shall be noted that the K-factors considered in the calculation are to be confirmed by the
final Battery Manufacturer.
1.8 125V DC Load data-
SUMMARY OF DC LOAD
SL. NO. DESCRIPTION 12 hrs 3 hrs 1 min >1min

1 330 KV CRP Panels 858 0 944
2 161 KV CRP Panels 688 0 944
3 330 KV Switchyard 276 0 27588 900
4 161 KV Switchyard 322 0 6524 300
5 LV Switchgears 350 0 1000
6 DC Lightning Load 0 2000 0
7 34.5kV CRP 192 0 552
8 34.5kV Switchyard 80 0 1960 1000
Watts 2766 2000 39512 2200
Amp 22 A 16A 316A 18A

1.9 125V DC- Duty Cycle Determination
Date: Sep09,
Project: K2BSP 161/34.5kV Switchyard 2010 Page: 1 of 1
Lowest Expected Minimum
Cell Cell Type:
Electrolyte Temp: 30 deg. C Voltage: 1.75 Cell Mfg: TBD Ld Calc Sized By: CCK
(1) (2) (3) (4) (5) (6) (7)
Required Section
Capacity at Size
(3) +
T Min Rate (6A)=Positive
(6A)
Amps/Pos
Change in Duration Time to End (Rt) Plates
Load Load of Period of Section or
(3) x(6B)=Rated
Amp
Hrs
(6B)m K
Period (amperes) (amperes) (minutes) (minutes) Factor (Kt) Pos Value Neg Value
Section 1 - First Period Only - IF A2 is greater than A1, go to
Section 2.
1 A1= 334 A1-0= 334 M1= 1M T=M1= 1M 0.86 287.24 ***
Sec 1
Total 287.24 ***
Section 2 - First Two Periods Only - IF A3 is greater than A2, go to Section 3.
1 A1= 334 A1-0= 334 M1= 1M T=M1+M2 180M 3.50 1169.00

2H
2 A2= 16 A2-A1= -318.00 M2= 59M T=M2= 179M 3.46 -1100.28
Sec
Sub Total 1169.00 -1100.28
2
Total 68.72 ***
Section 3 - First Three Periods Only - IF A4 is greater than A3, go to Section 4.
1 A1= 334 A1-0= 334 M1= 1M T=M1+M2+M3= 600M 10 3340.00

2H
2 A2= 16 A2-A1= -318.00 M2= 59M T=M2+M3= 599M 10 -3180
3 A3= 22 A3-A2= 6.00 M3= 7H T=M3= 420M 3.5 21.00
Sec
Sub Total 3361.00 -3180
3
Total 181.00 ***
Section 4 - First Three Periods Only - IF A5 is greater than A4, go to Section 5.
1 A1= A1-0= M1= T=M1+...M4=

2 A2= A2-A1= M2= T=M2+M3+M4=
3 A3= A3-A2= M3= T=M3+M4=
3 A4= A4-A3= M4= T=M4=
Sec
Sub Total
4
Total ***
Random Equipment Load Only (if needed)
R AR= 0 AR-0= 0 MR= 1M T=MR= 1M 0.00 0.00 ***
Maximum Random Uncorrected
Section Section Size Temp Design Aging
Size Size Corrected Marg Factor
(8) +(9) =(10) (11) *(12) * (13) *(14) =(15)
287.24 0.00 287.24 287.24 1.04 1.15 1.25 429.42
When the cell size (15) is greater than the standard cell size, the next larger cell is
required.
(A) - Positive Plates
Required cell size (16) 500
(B) - Ampere Hours Therefore cell (17) 62 is required.
1.11 125 V Battery Float Charger for 500 AH battery.
Battery Nominal Voltage = 125 V DC
Battery Charger current rating is the sum of the continuous load current and the float charger
current to the Battery
Battery Charger Rating = Continuous Load Current + Float Charging current for the Battery
Continues Load Current = 22 amps
Float Charging current = 2.0 mA per AH
For 500 Ah Battery Float current = 500x 2/1000 amps
= 1.0 amps
Battery Charger Rating = 22 + 1.0 = 23 amps
Rating of each battery charger selected considering design margin and future expansion shall be
23 x 1.25 x 1.15 = 33.06 Amps
Hence final Float Charger selected as 125 V , 40 amps
1.12 125V Battery Boost charger sizing for 500AH battery
Battery Nominal Voltage = 125 V DC
Battery Charger current rating is the sum of the continuous load current and
the boost charger current to the Battery
Battery Charger Rating = Continuous Load Current + Boost Charging current for the Battery
Continues Load Current = 22 amps
Boost Charging current = 0.2 x AH of the Battery
For 500 Ah Battery Boost current = 0.2x 500 amps
= 100 amps
Battery Charger Rating = 22 + 100 = 122 amps
Rating of each battery charger selected considering design margin and future expansion shall be
122 x 1.25 x1.15 = 175.37 Amps

Hence final Boost Charger selected as125 V , 180 amps
1 Battery selected as 125 V , 500 AH

2 Float Charger selected as 125 V , 40 amps
3 Boost Charger selected as 125 V ,180 amps
1.13 ANNEXURE
125V DC Power requirement Chart - 161kV Switchyard

Unit VA / Qty of Total VA /
Slno Device Duty Voltage W items W Remarks
Relays, Aux. Relays, Ind. Continuous
Lamps, Transducers, /
Annunciator, Hooter etc. Intermittent
A Disconnector switch
1 Main switch
a opening coil I 125V DC 7X1 14 98
b closing coil I 125V DC 7X1 14 98
2 Earth switch
B Circuit Breaker
a closing coil I 125V DC 300 7 2100
b Trip coil - 1 I 125V DC 300 7 2100
c Trip coil - 2 I 125V DC 300 7 2100
d Relays C 125V DC 7X1 7 49
e Auxiliary contactors C 125V DC 3X9 7 189
f Counters C 125V DC 2X3 7 42
g Lamps C 125V DC 2X3 7 42
Total DC (Cont.) 322

Total DC (Inter.) 6524

125V DC Power requirement Chart - 161kV Line Protection Panel
SL VA / Total VA /
No. Device Duty Voltage W Qty W Remarks
Relays, Aux. Relays, Ind. Lamps, Continuous
Transducers, Annunciator, Hooter etc. /
Intermittent
1 7SA522 C 125V DC 18 1 18
2 7SA6 C 125V DC 18 1 18
3 7SV6 C 125V DC 4 1 4
4 VAA11(dc supervision) C 125V DC 6 2 12
5 TTS cont. mult. Relay C 125V DC 6 2 12
6 VAJHM53(Trip relay) I 125V DC 50 3 150
7 VAX21(trip relay coil supn) C 125V DC 4 2 8
VAX31(trip ckt supervision
8 relay) C 125V DC 6 6 36
VAJS23(Single phase trip
9 relay) I 125V DC 12 10 120
10 7SS523 C 125V DC 40 1 40
11 7RW600 C 125V DC 4 1 4
VAJC11(voltage selection
12 relay) I 125V DC 3 2 6
13 6MD66(Bay control unit) C 125V DC 20 1 20
DC
Total (Cont.) 172
DC
Total (Inter.) 276
125V DC Power requirement Chart - 161kV Bus Bar Panel

Sr VA / Total VA /
no. Device Duty Voltage W Qty W Remarks
Transducers, Annunciator, Hooter /
etc. Intermittent
1 7SS522 C 125V DC 50 1 50
DC
Total (Cont.) 62
DC
Total (Inter.) -

125V DC Power requirement Chart - 161kV TR Protection Panel
SL VA / Total VA /
Intermittent
1 7UT613 C 125V DC 5 1 5
2 7SJ64 C 125V DC 16 1 16
3 relay) I 125V DC 3 2 6
5 7SV6 C 125V DC 4 1 4
6 VAA31(trf trouble mult relay) C 125V DC 6 5 30
9 relay) C 125V DC 6 6 36
10 7SS523 C 125V DC 16 1 16
11 RTCC I 125V DC 40 1 40
DC
Total (Cont.) 141
DC
Total (Inter.) 196

125V DC Power requirement Chart - 34.5kV Switchyard
Unit VA / Qty of Total VA /
Slno Device Duty Voltage W items W Remarks
Relays, Aux. Relays, Continuous
Ind. Lamps, /
Transducers, Intermittent
Annunciator, Hooter etc.
A Circuit Breaker
a closing coil I 125V DC 300 X 1 4 1200
b Trip coil - 1 I 125V DC 190 X 1 4 760

Total DC (Cont.) 80
Total DC (Inter.) 1960
125V DC Power requirement Chart - 34.5kV Line Protection Panel

SL VA / Total VA /
Intermittent
3 7SV6 C 125V DC 4 1 4
5 TTS cont. mult. Relay C 125V DC 6 2 12
8 relay) C 125V DC 6 6 36
9 VAJS23(Single phase trip relay) I 125V DC 12 10 120
11 7RW600 C 125V DC 4 1 4
12 relay) I 125V DC 3 2 6
DC
Total (Cont.) 96
DC
Total (Inter.) 276

125V DC Power requirement Chart - 330kV Switchyard (Future)
Unit VA Qty of Total VA /

Slno Device Duty Voltage / W items W Remarks
Transducers, Annunciator, /
Hooter etc. Intermittent
Disconnector (PG)
A switch
1 Main switch
2 Earth switch
C Circuit Breaker
a closing coil I 125V DC 300 X 3 6 5400
b Trip coil - 1 I 125V DC 1000 X 3 6 10800
c Trip coil - 2 I 125V DC 1000 X 3 6 10800
DC
Total (Cont.) 276
DC
Total (Inter.) 27588

125V DC Power requirement Chart - 330kV Line Protection Panel (Future)
SL VA / Total VA /
Intermittent
1 7SA522 C 125VDC 18 1 18
2 7SA6 C 125VDC 18 1 18
3 7SV6 C 125VDC 4 1 4
4 VAA11(dc supervision) C 125VDC 6 2 12
5 TTS cont. mult. Relay C 125VDC 6 2 12
6 VAJHM53(Trip relay) I 125VDC 50 3 150
7 VAX21(trip relay coil supn) C 125VDC 4 2 8
8 relay) C 125VDC 6 6 36
VAJS23(Single phase trip
9 relay) I 125VDC 12 10 120
10 7SS523 C 125VDC 100 1 100
11 7RW600 C 125VDC 4 1 4
12 relay) I 125VDC 3 2 6
13 6MD66(Bay control unit) C 125VDC 20 1 20
DC
Total (Cont.) 232
DC
Total (Inter.) 276

125V DC Power requirement Chart - 330kV ICT Protection Panel (Future)
SL VA / Total VA /
Intermittent
1 7UT613 C 125V DC 5 1 5
2 7SJ64 C 125V DC 16 1 16
3 relay) I 125V DC 3 2 6
5 7SV6 C 125V DC 4 1 4
6 VAA31(trf trouble mult relay) C 125V DC 6 5 30
9 relay) C 125V DC 6 6 36
10 7SS523 C 125V DC 16 1 16
11 RTCC I 125V DC 40 1 40
DC
Total (Cont.) 141
DC
Total (Inter.) 196
125V DC Power requirement Chart - 330kV Bus Bar Panel (Future)
Slno. Device Duty Voltage VA / W Qty Total VA / W Remarks

Transducers, Annunciator, Hooter /
etc. Intermittent
1 7SS522 C 125V DC 100 1 100

DC
Total (Cont.) 112
DC
Total (Inter.) -

125V DC Power requirement Chart
330kV Switchyard (Future)
Slno. Panel Name 125V DC Remarks

DC (Cont.) DC (Inter.)
1 Kintampo Line 232 276
2 Aboadze Line 232 276
5 ICT-1 141 196
6 ICT-2 141 196
13 Busbar 112 0
14 Switchyard 276 27588
GRAND TOTAL 1134 28532
161kV Switchyard

1 Aksombo Line 262 576
2 Kumasi Line 262 576
9 TR-1 141 606
10 TR-2 141 606
13 Busbar 142 0
7 Breaker failure 262 576
34.5kV Switchyard

1 ECG F1 Line 262 576
2 ECG F2 Line 262 576


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Volta River Authority, Ghana

VOLTA RIVER AUTHORITY,GHANA

0 Preliminary 09-09-2010 CCK LRP

KEC INTERNATIONAL LTD.

0 Preliminary 05-08-2010 CCK LRP

The following standard shall apply

1.3. System Particulars

1.3.1 Nominal Voltage 125V DC / 48V DC

1.3.2 Nominal cell voltage 2.00V/cell

1.3.3 End cell voltage at the of 10 hour Discharge 1.85V/cell

1.3.4 Discharge time 10 Hrs

1.4. Service Condition

The equipment to the specification shall be capable of operation under following

1.4.1 Maximum Ambient Temperature : 400C

1.4.2 Minimum Ambient Temperature : -10C

1.4.3 Average Ambient Temperature : +30 0C

1.4.4 Maximum relative humidity : 90 %

0 Preliminary 05-08-2010 CCK LRP

1.4.6 Maximum wind velocity : 120 km / hr

1.4.7 Isokeraunic level : 180 days

1.5 Input Data

Manufacturer’s catalogues for all the Protection Devices/Subsystems/Components give the

Battery sizing calculations is in four steps viz.

Step 3 -Duty Cycle Determination is based on the sequence of incidences.

Step 4 -Battery Sizing Estimation based on the above duty cycle.

1.7 Design Criteria

0 Preliminary 05-08-2010 CCK LRP

Category Brief Title Brief Description

L1 Continuous Standing Loads All Protection Relays

L2 Non-continuous Standing Loads Supply Of Emergency Lighting Loads

L3 Momentary Loads-Abnormal Simultaneous tripping of all 161 kV

c) Additional Capacity Allowances

Design Margin = 1.15

1.8 125V DC Load data-

SL. NO. DESCRIPTION 12 hrs 3 hrs 1 min >1min

2 161 KV CRP Panels 688 0 944

3 330 KV Switchyard 276 0 27588 900

4 161 KV Switchyard 322 0 6524 300

5 LV Switchgears 350 0 1000

6 DC Lightning Load 0 2000 0

7 34.5kV CRP 192 0 552

8 34.5kV Switchyard 80 0 1960 1000

Watts 2766 2000 39512 2200

Amp 22 A 16A 316A 18A

0 Preliminary 05-08-2010 CCK LRP

1 A1= 334 A1-0= 334 M1= 1M T=M1+M2 180M 3.50 1169.00

1 A1= 334 A1-0= 334 M1= 1M T=M1+M2+M3= 600M 10 3340.00

1 A1= A1-0= M1= T=M1+...M4=

Battery Nominal Voltage = 125 V DC

Continues Load Current = 22 amps

Float Charging current = 2.0 mA per AH

For 500 Ah Battery Float current = 500x 2/1000 amps

Battery Charger Rating = 22 + 1.0 = 23 amps

23 x 1.25 x 1.15 = 33.06 Amps

Hence final Float Charger selected as 125 V , 40 amps

1.12 125V Battery Boost charger sizing for 500AH battery

Battery Nominal Voltage = 125 V DC

Continues Load Current = 22 amps

Boost Charging current = 0.2 x AH of the Battery

For 500 Ah Battery Boost current = 0.2x 500 amps

Battery Charger Rating = 22 + 100 = 122 amps

122 x 1.25 x1.15 = 175.37 Amps