Battery Sizing Design Basis TCE

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(1)SECTION: TITLE. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET ( i ) OF (v). DC SYSTEM. DESIGN GUIDE FOR DC SYSTEM. TATA CONSULTING ENGINEERS 73/1, ST. MARK’S ROAD BANGALORE 560 001. FLOPPY NO FILE NAME. : TCE.M6-EL-FP-DOC-006 : M6-6000.DWG. REV.NO. R1. R2. R3. ISSUE. INITIALS. SIGN. INITIALS. SIGN. INITIALS. SIGN. PPD.BY. CPS. Sd/-. RRN. Sd/-. RRN. Sd/-. CKD.BY. DKB/DDRC. Sd/-. VS. Sd/-. VS. Sd/-. APP.BY. DKB. Sd/-. UAK. Sd/-. UAK. Sd/-. DATE. 92-09-04. 97-03-31. INITIALS. SIGN R3. 99-03-02 FORM NO. 020R2.

(2) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SECTION: REV. STATUS. SHEET (ii ) OF (v). DC SYSTEM. REVISION STATUS REV. NO. DATE. R3. 99-03-02. DESCRIPTION. 1.Design guides for Lead Acid battery-(M6-EL-BT-6000 R2),NiCad battery (M6-EL-BT-6000A R1) and battery Chargers(M6-EL-BC-6004 R2) have been combined to make a composite design guide on the ‘DC System’. 2. In addition the loads considered for emergency lighting , auxiliary relays and indicating lamps have been revised. 3.Section 4.0 providing recommendation for quantities of batteries in different installations has been revised.. ISSUE R3 FORM NO. 120 R1.

(3) SECTION: CONTENTS. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET (iii) OF (v). DC SYSTEM. CONTENTS PART-A LEAD ACID BATTERY SL.NO. 1.0. TITLE SCOPE. SHEET NO. 2. 2.0. TYPES OF LEAD ACID CELLS. 2. 3.0. SELECTION OF DC VOLTAGE LEVELS. 3. 4.0. QUANTITIES OF BATTERIES. 5. 5.0. AMPERE HOUR CAPACITY SIZING. 6. 6.0. INSTALLATION OF BATTERY. 11. 7.0. REFERENCES. 13. APPENDIX-1 TYPICAL EMERGENCY LOADS. 14. APPENDIX-2 RATING AND DESIGNATION. 16. CAPACITIES AND DIMENSIONS OF TUBULAR CELLS. 18. CAPACITIES AND FINAL CELL VOLTAGE OF HDP TUBULAR CELLS AT VARIOUS RATES OF DISCHARGE AT 27deg.C. 19. CAPACITIES AT 27deg.C AT VARIOUS RATES OF DISCHARGE OF TYPE II HDP CELLS (TUBULAR). 20. PERFORMANCE CURVES TYPE-II HDP CELLS (TUBULAR). 21. CAPACITIES AND DIMENSIONS OF PLANTE CELLS. 23. APPENDIX-3 BATTERY SIZING - SAMPLE CALCULATION. 24. APPENDIX-4 TYPICAL BATTERY ROOM PLAN. 31. SAMPLE WORK SHEET. 32. ISSUE R3 FORM NO. 120 R1.

(4) SECTION: CONTENTS. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET (iv ) OF (v). DC SYSTEM. CONTENTS PART-B NICAD BATTERY SL.NO. 1.0. TITLE SCOPE. 2.0. DIFFERENT TYPES OF NICAD CELLS. 35. 3.0. PERFORMANCE CHARECTERISTICS. 35. 4.0. APPLICATIONS OF NICAD BATTERIES. 38. 5.0. MODE OF OPERATION. 39. 6.0. NUMBER OF CELLS. 40. 7.0. OTHER CONSIDERATIONS FOR SIZING NICAD BATTERIES. 41. 8.0. INSTALLATION. 42. 9.0. BATTERY SIZING CALCULATIONS. 43. 10.0. SPECIFYING THE BATTERY. 44. 11.0. REFERENCES. 45. APPENDIX-1 CELL DESIGNATION. SHEET NO. 35. 46. PREFERRED DIMENSIONS. 47. DISCHARGE DATA FOR NICAD BATTERY (L,M & H TYPE CELLS). 48. TEMPERATURE CORRECTION FACTOR CURVES APPENDIX-2 SAMPLE CELL SIZING CALCULATION CELL SIZING WORK SHEET. 64 67 69. APPENDIX-3 COMPARISION OF NICAD BATTERIES WITH LEAD ACID BATTERIES. 71. SAMPLE WORK SHEET. 72. ISSUE R3 FORM NO. 120 R1.

(5) SECTION: CONTENTS. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET (v ) OF (v). DC SYSTEM. CONTENTS PART-C BATTERY CHARGER SL.NO.. TITLE. SHEET NO.. 1.0. SCOPE. 75. 2.0. RECOMMENDED PRACTICE. 75. 3.0. DISCUSSION. 79. 4.0. ENCLOSURES i) FLOAT CUM BOOST CHARGER WITH 2 x 100% BATTERIES ii). iii). TCE.M2-EL-CW-S-2631 R0. FLOAT CUM BOOST CHARGER WITH 1 x 100% BATTERY. TCE.M2-EL-CW-S-2632 R0. FLOAT AND BOOST CHARGER WITH 1 x 100% BATTERY. TCE.M2-EL-CW-S-2633 R0. ISSUE R3 FORM NO. 120 R1.

(6) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: Facing Sheet SHEET. 1. OF 79. PART – A : LEAD ACID BATTERY. PART-A LEAD ACID BATTERY. ISSUE R3 FORM NO. 120 R1.

(7) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 2. OF 79. PART – A : LEAD ACID BATTERY. 1.0. SCOPE This design guide outlines the recommendation for the determination of voltage level, capacity, quantities and installation of DC battery of lead acid storage type required for providing DC power supply to essential services in the plant when the normal power supply fails. This also gives consideration to the safe shut down of the plant as well as human safety.. 1.1. This section (Part –A) of this guide pertains to lead acid batteries and also includes a few recommendations applicable to NiCad batteries also like selecting voltage levels. The sizing criteria for Nickel Cadmium batteries are dealt in Part – B of this design guide and Part – C of this guide covers details about Battery chargers .. 2.0. VARIOUS TYPES OF LEAD ACID CELLS. 2.1. The plante type cells are more rugged, need less maintenance and have a life expectancy of about 15-18 years, which is 5-7 years longer than that for tubular type. However, the plante type battery is costlier than the tubular type. All the manufacturers make tubular cells while very few manufacturers make plante cell.. 2.2. The cells with tubular plate construction are smaller in size than the plante type for a given AH rating.. 2.3. The following types of tubular cells are available in the market in addition to standard variety : a) b) c). High Discharge Performance (HDP) Maintenance Free-Valve Regulated (MF-VR) Low-Maintenance (LM) type. 2.4. The capacity of HDP cells under short duration discharge conditions are higher than that of normal tubular batteries and are comparable to that of Plante type batteries. Hence the capacity of battery required will be smaller than that with the standard performance cells for applications requiring high discharge currents for short duration. Hence these cells are preferred for power plant applications.. 2.5. The MF-VR cells require minimal attention from operation / maintenance staff and are stated to need no topping up of distilled water and no regular equalising charges. This type is well suited in ISSUE R3 FORM NO. 120 R1.

(8) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 3. OF 79. PART – A : LEAD ACID BATTERY. the plants where organised maintenance is infrequent. The low maintenance cells have grids made of low-antimony lead and require topping up only once in a year or so even at higher float voltages like 2.25 VpC. Hence this type also is well suited for plants where organised maintenance is infrequent or standalone substations in the distribution system or medium or small scale industries or where battery capacity is less than 300/500 AH. 2.6. The operating experience of the MF-VR and LM type cells for large capacities is limited and very few manufacturers make the same. Hence the sizing of these cells is not being discussed in the present guide and use of these cells may be decided on case to case basis.. 2.7. The recommended float voltage for lead acid batteries is between 2.16 V and 2.25V/ cell. The recommended boost charging duration is 10 hours in case of smaller capacity batteries and 14 to 16 hours for larger capacities (1000 AH and above). The recommended maximum boost charger voltage is 2.75 V/cell. The recommended equalising charge voltage is 2.33 VpC.. 3.0. SELECTION OF DC VOLTAGE LEVELS. 3.1. The voltage level selection for the plant shall consider the following aspects :. 3.2. a). Quantum of power. b). Individual load point power ratings, quantum of such load points and the geographic spread of the load points. c). Standard voltages suitable for the equipment. For the same power requirement, the battery room size, and battery cost with higher voltage will be higher than those with lower voltage. However, the lower voltage requires higher current for the loads and hence to meet this current and to limit the voltage drop within limits cable sizes will be higher than those with higher voltage. Considering all the aspects following voltage levels are recommended.. ISSUE R3 FORM NO. 120 R1.

(9) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SECTION: WRITEUP SHEET. DC SYSTEM. 4. OF 79. PART – A : LEAD ACID BATTERY. 3.2.1 Power Plant 3.2.1.1 Large power plants (Coal based) a). For electrical power, control & protection requirements. -. b). I&C system. Normally most of the I&C vendors' systems are suitable for +24V or 48V DC.The voltage level shall be fixed after I&C system requirement is finalised.. c). Isolated auxiliary plants. -. 30 V DC or 110 V DC like raw water pump house (dedicated battery if running lengths of cables from the main plant is comparatively much higher). d). Switchyards. -. 220 V DC (If switchyard has got separate control building). e). Coal handling plant. -. 110 V DC/220 V DC. 3.2.1.2 Gas based/diesel/Hydro. -. 110 V/220 V DC power plants including captive power plants. 3.2.2. 220 V DC. Industrial Plants a). Large plants with many load points and distributed in large area. 220 V DC. b). Small plants with multiple load points and outdoor substations. 110 V DC. c). Small plants with very few switchboards / load points. 30 V DC. d). For process control. Generally 24/48V (As required by the I&C system design). -. ISSUE R3 FORM NO. 120 R1.

(10) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 5. OF 79. PART – A : LEAD ACID BATTERY. 4.0 4.1 4.1.1. 4.1.2. QUANTITIES OF BATTERIES Power Plants a) In case of unit sizes upto 250 MW, each unit shall be provided with one battery and also, a separate battery shall be provided for the common services of these units and switchyard load. The unit and common services batteries shall be sized to cater one unit and station service loads so that one serves as a standby to the other. b). For instrumentation and control system two 100% batteries for each unit shall be provided.. c). If switchyard is having a separate control building one 100% battery shall be provided for the switchyard. In addition switchyard DCDB will be provided with a tie feeder from station DCDB (as a standby).. d). One no. 100% rating battery shall be considered for coal handling plant DC power requirements.. For large power units (500 MW and above) and nuclear power plants, for each unit, the 220V DC unit loads shall be divided into two categories, e.g. a). D.C. power loads comprising D.C. motor drives, solenoids, emergency lighting , etc.. b). D.C. control loads comprising tripping and closing circuits, indicating lamps, protection and control panels, safetysupervisory systems etc.. Each category of loads will be catered to by a separate 220V battery and battery charger system. There will be three 50% rated batteries.Each battery is capable of catering to 50 % power loads of unit ( since the power load requirement of 500MW unit is very huge ) and entire control load of unit. Normally two of the three batteries will cater power loads and the third one will be catering control loads. For switchyard load there will be a seperate 100% battery feeding switchyard loads.It is recommended to provide a tie from DCDB of control loads to DCDB of switchyard. One number 100% battery shall be considered for coal handling plant DC power requirement.. ISSUE R3 FORM NO. 120 R1.

(11) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 6. OF 79. PART – A : LEAD ACID BATTERY. 4.1.3. Gas Power Plants The battery and charging equipment for each gas turbine is supplied by gas turbine supplier as part of the package.It is recommended to have each unit battrery rated to cater two gas turbine units.and a tie feeder is provided between one unit DCDB to another unit DCDB. The station and STG DC loads shall be catered by provision of 2X100% batteries . If switchyard and station building is seperate from the main plant control building a seperate 1X 100% dedicated battery shall be recommended. For catering I&C loads , it is recommended to have 2X 100% rated batteries for each unit.. 4.1.4. Separate batteries with chargers are required to be provided for UPS for power plants. For details please refer to design guide M6-CL-AUG-715-6011 for UPS.. 4.2. Industrial Plants and Small Power Plants Two 1X 100% rated batteries to cater for all the emergency power, control and protection requirements of the plant. Shall be provided. However, it shall be firmed up based on the quantum of the load points and their geographic location. A separate battery may be required for instrumentation, control and annunciation requirement for process purposes. The specific requirements in each case shall be ascertained. Separate batteries with chargers are required to be provided for UPS for Industrial and Small power plants. Possibility of using the same station battery for UPS as well may be explored on a case to case basis.. 4.3. The recommendations on quantities are included int Part – C of this design guide in Tabular form.. ISSUE R3 FORM NO. 120 R1.

(12) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 7. OF 79. PART – A : LEAD ACID BATTERY. 5.0. AMPERE HOUR CAPACITY SIZING. 5.1. The capacity of a cell or battery as defined in Indian standards 1651 & 1652 is expressed in Ah, at 27deg.C, attainable when the cell or battery is discharged at the 10-hour rate to an end voltage of 1.85 V per cell. The capacity is a function of number of positive plates per cell.. 5.2. The battery capacity is influenced by the factors listed below. a) b) c) d) e). 5.2.1. Duty cycle End of the duty cycle voltage Temperature correction factor Compensation for ageing Design margin. Duty cycle a). At the time of power supply failure, the battery is required to supply D.C. power requirements of essential circuits for safe shut down of the station, vital instrumentation, controls, communication system, DC annunciation and emergency lighting.. b). In power plants and some industrial plants an emergency diesel generator is available, which will provide a.c. power to the battery charger after the period required to start and connect it to the emergency AC bus. However, the battery size shall be calculated on the assumption that the engine driven generator may fail to start or operate satisfactorily.. c). The duration for which each type of D.C. load will have to be supplied by battery when the normal power supply fails is different. The same may be continuous or for short time duration or momentary. In a typical power plant the DC power, control & protection loads and their classification based on duration for which they need to be supplied are as follows. Time duration i). Upto 1 minute. Loads (Amperes) *. Trip relay / Trip coil currents of circuit breakers.. ISSUE R3 FORM NO. 120 R1.

(13) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 8. OF 79. PART – A : LEAD ACID BATTERY. *. Starting currents of all automatically started D.C. motors.. *. DC motor operated emergency steam stop valves.. *. Solenoid valves for isolation, safety relief, minimum recirculation etc.. *. Inrush currents of supervisory safety system for fuel, turbine and generator controls.. ii). Upto one(1) hour. * * *. Emergency oil pump Jacking oil pump Steam generator control panels (including FSSS, Mill panels). iii). Upto two(2) hours. * * * * *. D.C. seal oil pump Scanner air fan D.C. emergency lighting P.A. system Annunciation (20%). iv). Upto 10 hours. *. * * •. d). Indicating lamps / Semaphore indicators in switchgears/control panels Control room emergency lighting Annunciation (10%) Auxiliary relay ( which are likely to be energized during black out condition ). A table of loads indicating their power requirement and duration shall be prepared and a load curve for the battery shall be established. Appendix-1 indicates a table for typical emergency DC loads. Appendix-3 indicates a list of equipment and their typical D.C. loads for a 210 MW unit. It is recommended that project specific loads for DC motors, T.G. & S.G. vendor loads and inrush currents shall be obtained before proceeding with the sizing.. ISSUE R3 FORM NO. 120 R1.

(14) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 9. OF 79. PART – A : LEAD ACID BATTERY. e). 5.2.2. I&C battery for power plant application shall be sized to cater the loads for half hour. The loads to be considered shall be the maximum load of I&C system at any operating condition viz starting, running and tripping/stopping.. End of duty cycle voltage a). The allowable end of duty cycle voltage of a battery has a major role in determination of the capacity of the battery. This in turn is dependent on the limits of system voltages that can be withstood by D.C. equipment. The D.C. equipment are generally rated to operate between +10% and -15% of their rated value with certain exceptions like trip coils and trip relays which can accept lower voltages.. b). Manufacturers recommend a float voltage ranging from 2.06V to 2.3 volts per cell, for different float voltage adopted, the required frequency of equalising charges are given below. -----------------------------------------------------------------------------------Float Voltage Per Cell Approximate periodicity of equalising charges ----------------------------------------------------------------------------------2.25 No equalising charges 2.20 12 months 2.15 3 months 2.10 1 month 2.06 2 weeks ---------------------------------------------------------------------------------. c). It is desirable to keep the float voltages as high as the D.C. system can accept to minimise frequency of equalising charges. It is recommended to keep a float voltage of 2.2V per cell. However, this shall be confirmed from the battery supplier specific to the project. i). ii). Considering the above, the number cells of a battery are selected as : Max.allowable DC voltage - Regulation due to charger --------------------------------------------------------------Float voltage per cell The end of duty cycle cell voltage is determined ISSUE R3 FORM NO. 120 R1.

(15) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 10. OF 79. PART – A : LEAD ACID BATTERY. by Min. allowable D.C. voltage + Cable drop ------------------------------------------------No. of cells d) Sl. No 1. 2. Typical values for 220V DC system and 24V DC systems are given in the table below: System Max.allow Min.allowable No.of End of duty cycle voltage cells voltage able voltage 220V 242V 187V 108 1 min - 1.75V / cell 1,2 HRS & 10 hours 1.85V/cell 24V 30V* 21.5V* 13 1.8V/cell. * To be ascertained on project to project basis Note : For 110V & 30V plant DC systems, the details can be worked out in the same manner as for 220V system above.. 5.2.3. e). The cable drop to be considered in DC system shall be 2% from the charger/battery to Distribution board and 3% from board to any feeder in case of 220V DC system.. f). In case of 24V DC system to keep the voltage drop within 5% limit, the cable sizes between DC board and I&C cabinets are very large and sometimes impractical to terminate. Hence for 24V system a total drop of 7.5% (2.5% between board and charger/battery and 5% between board and individual loads) is recommended.. Temperature correction factor The standard temperature for stating cell capacity is 27deg.C. If the lowest expected electrolyte temperature is below 27deg.C, a cell large enough to have the required capacity available at the lowest expected temperature shall be selected. The lowest electrolyte temperature shall be considered as 10o above minimum ambient temperature. If the lowest expected temperature is above 27deg.C, no correction factor shall be applied. The correction factor shall be calculated according to the formula: ISSUE R3 FORM NO. 120 R1.

(16) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 11. OF 79. PART – A : LEAD ACID BATTERY. Correction factor = / K \ for the lowest | 1 + -------- (27-T) | expected electrolyte | 100 | temperature, Tdeg.C \ / The factor 'K' for plante cells is 0.9 and for tubular, 0.43. The minimum electrolyte temperature (T) shall be considered as 10deg.C higher than the minimum ambient air temperature at site. 5.2.4. Compensation for age ANSI/IEEE STG.450-1270 recommends that a battery be replaced when its actual capacity drops to 80% of its rated capacity. Hence a factor of 1.25 shall be considered for ageing.. 5.2.5. Design margin When the D.C. loads are more or less final at the time of battery sizing for tender specification purposes and/or the battery sizing is being done for a similar plant already executed, no design margin is considered necessary. If the sizing is being done for a new type of project or with very little confirmed loads, a design margin of 10 to 15% shall be provided over the final capacity arrived. While sizing the battery for nuclear power plant applications, it shall be noted that the "margins" required by IEEE STD.323-1273. 6.3.15 & 6.3.3 are to be applied during "Qualification" and are not related to "design margin".. 5.3. Calculation of Ampere Hour Capacity The plante and tubular high discharge performance cells have better capacity factors at the short duration discharges (1 hour, 2 hours etc.). For durations less than one hour, the above types of cells have higher capacity factor than the tubular standard discharge performance cell. Hence for power plant application and for applications where short duration loads are appreciable high discharge performance cell shall be used. The capacity of the battery shall then be determined in accordance with the procedure outlined in Appendix-3.. ISSUE R3 FORM NO. 120 R1.

(17) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 12. OF 79. PART – A : LEAD ACID BATTERY. 6.0. INSTALLATION. 6.1. Battery cells shall be installed in a separate battery room, preferably near the D.C.load. The 24V batteries shall be in the same floor as I&C cabinets and as near as possible. Fig.4 included in design guide TCE.M6-EL-PJ-G-SG-6602 R1 (GA of Turbine Building Electrical Equipment & Space Organisation) indicates a typical battery Room Plan (Copy of Fig.4 enclosed as Appendix-4 for ready reference).. 6.2. The flooring shall be provided with acid resistance tiles, a dished floor drain and drainage piping for collecting spilled acid. The spilled acid shall be diluted before discharging to the outside storm water drainage system.. 6.3. Acid proof paint shall be provided on walls upto 2.3m height.. 6.4. A wash basin shall be provided for emergency drenching of face and body.. 6.5. The total capacity of exhaust fans (suitably distributed) should be minimum 1/10th of the total volume of the battery room per minute. The exhaust shall be directly outside the building. However, specific requirements shall be obtained from the battery manufacturer.. 6.6. Separate cable(s) shall be provided for each polarity of the outgoing battery leads. If the cables are unarmoured they shall be taken in separate conduits and the conduits shall be PVC coated for protection against corrosion. Routing of any cables in cable-trays through battery room shall be avoided.. 6.7. Adequate provision for storage of acid, distilled water, instruments, accessories, etc. should be provided in the battery room.. 6.8. During float or boost charging of the lead acid battery hydrogen gas is generated. The volume of hydrogen gas generated depends on the amount of charging current. Also, the float current demand of a fully charged battery will double approximately for every 10deg.C rise above the base temperature of 27deg.C. Each fully charged cell produces 4.5 x 10-4 Cu.m (0.016 Cu.pt) hydrogen gas per hour per charging amperes in an ambient of 25deg.C to 27deg.C. Hydrogen explosive concentration is reached if the explosives mixture is three percent of the volume of room air.. ISSUE R3 FORM NO. 120 R1.

(18) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 13. OF 79. PART – A : LEAD ACID BATTERY. 6.9. In view of the presence of hydrogen gas, warning signs shall be installed outside and inside the room prohibiting smoking, sparks of flame.. 6.10. Lighting fixtures shall be vapour-proof type with reflectors painted with anticorrosive epoxy-paint. Lighting switch should be outside the battery room.. 7.0. REFERENCES. 7.1. IS:1651-1991. :. Stationary cells and batteries,lead-acid type with Tubular positive plates Specification.. 7.2. IS:1652-1991. :. Stationary cells and batteries, lead-acid type with Plante' positive plates Specification.. 7.3. IEEE Std 485-1273 :. Recommended practice for sizing large lead acid storage batteries for Generating Stations and Sub-stations.. 7.4. IS:8320-1272. :. General requirements and methods of tests for lead-acid storage batteries. 7.5. IS:1885-1965. :. Electrotechnical vocabulary Secondary cells and batteries.. 7.6. IEEE Std. 450-1270 :. Recommended practice for maintenance testing and replacement of large lead storage batteries for generating stations and sub-stations.. 7.7. IEEE Std. 484-1271 :. Recommended practice for Installation design and installation of large lead storage batteries for generating stations and substations.. 7.8. IEEE Std. 323-1273 :. IEEE Standard for Qualifying class-1E Equipment for Nuclear Power Generating Stations.. ISSUE R3 FORM NO. 120 R1.

(19) SECTION: APPENDIX - 1. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 14. OF 79. PART – A : LEAD ACID BATTERY. APPENDIX-1 TYPICAL EMERGENCY LOADS. 1. a) Bearing oil pump b) Bearing oil pump for BFPT c) Bearing oil pump for MBFP. STEAM TG 500MW 120MW 13kW 15kW 2x5.5kW --11kW ---. 2. a) Seal oil pump b) Seal water pump for BFPS. 13kW 60kW. 10kW ---. 11kW ---. 3. Jacking oil pump. 35kW. 37KW. 28KW. 4. Scanner air fan. ----. 4.4KW. 7.5KW. 5. Inverter for instruments. 5kW. 10kW. 6. Inverter for PA system. 2kW. 2kW. 2kW. 7. Carrier panels. <-----------. 8. Auxiliary relay (each). <-----------. 150watt/ ---------> panel 3watts --------->. 9. Auxiliary contactor (each). <-----------. 10watts. --------->. 10. DC emergency lights. <-----------. Approx. 10% of normal lighting. --------->. 11. UPS load (Incl. DAS, transmitters, controllers). 55kVA. 45KVA. 30kVA. 210MW 13kW -----. .. ISSUE R3 FORM NO. 120 R1.

(20) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX - 1 SHEET. 15. OF 79. PART – A : LEAD ACID BATTERY. APPENDIX-1 (Cont’d) TYPICAL EMERGENCY LOADS. 500MW. STEAM TG 120MW 210MW. 1. Continuous Loads Annunciator window (each). 2. Indicating lamp (each). ß -----5-10W For filament type ----à ß ----1 W For cluster LED type type ---à. 3. Auxiliary relays (each). <--------------------3W--------------------------à. 4. Auxiliary contactors (each). <--------------------10W-----------------------à. 5. Semaphore indicator (each). <--------------------3W------------------------à. 6. Control room emergency lighting. <---------------------1kW---------------------à. 7. FSSS load. ß-------------------10kW---------------------à. ß---------------------5W -----------------à. NOTES: 1.. The data for 120MW and 210MW units are taken from the designed data for GIPCL and Bhatinda units. All DC motor loads, electromagnetic valve loads, FSSS loads, instrumentation & control, UPS loads, other turbine generator supervisory loads should be as far as possible ascertained from the manufacturers.. 2.. When starting currents of DC motors are not available it may be assumed as 3.5 x FL current. If step resistor starting is provided the starting current may be assumed as 2.5 x FL current.. 3.. Instrumentation and control loads and annunciation loads may be on a separate 48 V / 24V battery.. 4.. For 210 MW unit loads also refer Appendix-3.. ISSUE R3 FORM NO. 120 R1.

(21) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SECTION: APPENDIX-2 SHEET. DC SYSTEM. 16. OF 79. PART – A : LEAD ACID BATTERY. APPENDIX-2 CELL DATA RATING AND DESIGNATION 1. Ampere-Hour Rating The rating assigned to the cell shall be the capacity expressed in ampere-hours (after correction to 27deg.C) stated by the manufacturer to be obtainable when the cell is discharged at the 10hour rate (C10) to a final voltage of 1.85 voltage.. 2.. Designation The cell shall be designated by symbols given below, arranged in the following sequence : Type of Positive Plate (See 2.1). Ah Rating of Cell (See 2.2). Type of Container (See 2.3). Notes: 1.. The plates are not replaced in this type of construction therefore, this designation does not include the number of positive plates; and. 2.. The designation of partially plated cells is not being standardized because partial plating of cells in this type of construction is not done.. 2.1. The positive plates shall be designated by the letter 'T' for tubular and 'P' for plante.. 2.2. The capacity rating shall be indicated by a number equal to the capacity in Ah.. 2.3. The material of container shall be designated by any one of the following letters as the case may be : G - for glass; H - for hard-rubber; P - for plastics; ISSUE R3 FORM NO. 120 R1.

(22) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-2 SHEET. 17. OF 79. PART – A : LEAD ACID BATTERY. W - for wood, lead-lined; or F - for fibre reinforced plastics (FRP) Example : T 400H HDP - designates a high discharge performance cell having tubular positive plates and a capacity of 400 Ah at 10 hour rate in hard-rubber container. SOURCE : IS 1651 & 1652 - 1991. ISSUE R3 FORM NO. 120 R1.

(23) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-2 SHEET. 18. OF 79. PART – A : LEAD ACID BATTERY. APPENDIX-2 (Cont’d) CELL DATA Capacities and Dimensions of Tubular Cells ----------------------------------------------------------------------------------------------Capacity at Maximum Overall Dimensions 10-Hour Rate ---------------------------------------------------------------------Length Width Height (1) (2) (3) (4) Ah mm mm mm --------------------------------------------------------------------------------------------20 105 170 365 40 105 170 365 60 140 170 365 80 165 190 365 100 190 190 450 120 190 190 450 150 190 190 550 200 265 215 550 300 320 215 550 400 380 215 550 500 390 235 550 600 390 235 715 800 515 235 715 1000 515 300 750 1500 450 400 865 2000 500 450 865 2500 650 450 865 4000 900 480 1240 5000 900 480 1240 6000 900 500 1240 7000 1100 500 1240 8000 1100 500 1240 --------------------------------------------------------------------------------------------NOTES : 1.. The length and width dimensions given in this table may be interchanged.. 2.. In the case of batteries with built-in cell connectors, the height of the interconnector shall be disregarded. ISSUE R3 FORM NO. 120 R1.

(24) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-2 SHEET. 19. OF 79. PART – A : LEAD ACID BATTERY. 3.. For capacities not covered in this table, the cell dimensions shall not exceed the dimensions of the cell of next higher size covered by this table. SOURCE : IS 1651 - 1991 APPENDIX - 2 (Cont’d) Standard Discharge Performance Cells (Tubular). Capacities and Final Cell Voltage at various rates of discharge at 27deg.C ------------------------------------------------------------------------------------------Period of Capacity Ratio : Capacity Final Discharge Ah capacity (CT) Rating Factor Cell Hours (T) divided by the 10hr (KT) = (1/2) Voltage Rated capacity (C10) (Volts) (1) (2) (3) (4) --------------------------------------------------------------------------------------------1 0.500 2 1.75 2 0.633 3.16 1.78 3 0.717 4.18 1.80 4 0.782 5.12 1.81 5 0.833 6.00 1.82 6 0.879 6.83 1.83 7 0.917 7.63 1.83 8 0.950 8.42 1.84 9 0.979 9.19 1.84 10 1.0 10 1.85 -------------------------------------------------------------------------------------------Source : IS 1651-1991. ISSUE R3 FORM NO. 120 R1.

(25) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SECTION: APPENDIX-2 SHEET. DC SYSTEM. 20. OF 79. PART – A : LEAD ACID BATTERY. APPENDIX - 2 (Cont’d) CELL DATA Capacities at 27deg.C at various rates of discharge Type II High Discharge Performance (HDP) Cells (Tubular) ------------------------------------------------------------------------------------------------Period of Capacity Ratio : Capacity Final Remarks Discharge Ah capacity (CT) Rating Factor Cell Hours (T) divided by the 10hr (KT) = (1/2) Voltage Rated capacity (C10) (Volts) (1) (2) (3) (4) ------------------------------------------------------------------------------------------------1/60 (1 min) 0.022 0.76 1.75 } M/s Chloride 1/2 (30 min) 0.368 1.36 1.75 } India 1. 0.60 0.488 0.392. 1.67 2.05 2.55. 1.75 1.80 } M/s Chloride 1.85 } India. 2. 0.738 0.714 0.597. 2.71 2.80 3.35. 1.78 1.80 } M/s Chloride 1.85 } India. 3. 0.811. 3.77. 1.80. 4. 0.862. 4.13. 1.81. 5. 0.90. 5.55. 1.82. 6. 0.93. 6.45. 1.83. 7. 0.951. 7.361 1.83. 8. 0.971. 8.239 1.84. 9. 0.988. 9.109 1.84. 10 1.0 10.0 1.85 ---------------------------------------------------------------------------------------------Source : IS 1651-1991 & Capacity Rating curves from M/s Chloride India. NOTE : The above data is applicable for plante cells also. The capacities for Type-I HDP cells are same as above for discharge rates of 3 hour, 5 hour and 10 hours (ISS does not specify capacities at other discharge rates for Type-I cells).. ISSUE R3 FORM NO. 120 R1.

(26) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-2 SHEET. 21. OF 79. PART – A : LEAD ACID BATTERY. TYPICAL CELL PERFORMANCE CURVES (SH-1). ISSUE R3 FORM NO. 120 R1.

(27) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-2 SHEET. 22. OF 79. PART – A : LEAD ACID BATTERY. ISSUE R3 FORM NO. 120 R1.

(28) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-2 SHEET. 23. OF 79. PART – A : LEAD ACID BATTERY. APPENDIX - 2 (Cont’d) CELL DATA Capacities and Dimensions: Plante Cells ----------------------------------------------------------------------------------Capacity at Maximum Overall Dimensions 10-Hour Rate ---------------------------------------------------------Length Width Height (1) (2) (3) (4) Ah mm mm mm ----------------------------------------------------------------------------------20 130 140 225 40 205 140 225 60 205 140 225 80 175 235 370 100 175 235 370 120 175 235 370 150 175 235 370 200 210 235 370 300 290 235 370 400 365 235 370 500 375 310 625 600 375 310 625 800 375 335 625 1000 385 375 635 1500 520 390 635 2000 650 390 635 2500 785 405 130 4000 1160 405 130 5000 1350 515 650 ----------------------------------------------------------------------------------NOTES : 1.. The length and width dimensions given in this table may be interchanged.. 2.. For capacities not covered in this table, the cell dimensions shall not exceed the dimensions of the cell of next higher size covered by this table. Source : IS 1652-1995. ISSUE R3 FORM NO. 120 R1.

(29) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-3 SHEET. 24. OF 79. PART – A : LEAD ACID BATTERY. BATTERY DUTY CYCLE DIAGRAM L 4 = 9 0 0 A. L6 = 84 A. L5 = 186 A. L3 = 46A. L2 = 30A L1 = 13 A SECTION-1. 60. 1. 120. 600. SECTION-2 SECTION-3 SECTION - 4 DURATION ( MIN ). ISSUE R3 FORM NO. 120 R1.

(30) SECTION: APPENDIX-3. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 25. OF 79. PART – A : LEAD ACID BATTERY. APPENDIX - 3 SAMPLE CALCULATION FOR SIZING OF A THERMAL POWER STATION 220V UNIT BATTERY (210 MW). LOAD TABULATION Sl. no. Load description. Qty.. Rating Watts. 1 min. 1 hr.. I.. UNIT LOADS. 1.. Tripping loads ( Prot. Relay + Trip Relay + CB Trip coil ). a.. 6.6 kV CBs. 34. 300. 10,200. b.. 415 V CBs. 7. 250. 1,750. 2.. Turb. Generator. a.. E.O.P.. 1. 13,000. 32,500*. 13,000. b.. DC seal oil pump. 1. 11,000. 27,500*. -. c.. Jacking oil pump. 1. 28,000. 70,000*. 28,000. d.. Others. 2,000. 2,000. 3. Steam generator. 10,000. -. 2hrs.. 10 hrs.. 11,000. 10,000. DC CSP (includes FSSS, mill panel) 4.. Main steam stop valve. 2. 4,000. 10,000. 5.. Scanner air fan. 1. 7,500. 18,750 *. -. 7,500. 6.. Emergency lighting. -. -. 5000. 7.. Indicating lamps. 400. 1#. 8.. Annunciation windows. 10. 5. 9.. Auxiliary relays. LS. LS. 1000 400. 100. 50 600 (200 nos @ 3W each ). ISSUE R3 FORM NO. 120 R1.

(31) SECTION: APPENDIX-3. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 26. OF 79. PART – A : LEAD ACID BATTERY. II. STATION LOADS. 1.. Tripping loads 6.6 kV CBs. 70. 300. 21,000. 415 V CBs. 12. 250. 3,000. 2.. Indicating lamps. 500. 1 #. 3.. PA system. LS. LS. 4.. Auxiliary relays. LS. LS. 500 2,000 300 (100 nos @3W each ). TOTAL AMPS. 894. 232. 116. 13. * #. Starting currents of motor ( 2.5 times the rated current ) Cluster LED type indicating lamps. 2.0. SIZING CALCULATION. 2.1. Battery duty cycle diagram in Sh.24 is constructed as detailed below from the above DC emergency load list for a typical 210 MW unit.. 2.2. Analysis of load data in Sh.25&26 indicates the distribution of loads with duration as under : Load. Sl. no. Duration. 1. 0 – 10 hrs.. 2850 W. 13A. 2. 1 min. - 2 hrs.. (11000+7500) =18500W. 84A. 3. 0 – 2 hrs.. (5000-1000) + (100- 50) + 2000 = 6500W. 30A. 4. 1 min. - 1 hr.. (28000+13000) = 41000 W. 186A. 5. 0 – 1 hr.. (51000 -(13000+28000)) =10000 W. 46A. 6. 0 - 1 min.. 196680 W. 894A. In Watts. in Amperes. NOTE: These loads are arrived at taking care to see that loads are not ISSUE R3 FORM NO. 120 R1.

(32) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-3 SHEET. 27. OF 79. PART – A : LEAD ACID BATTERY. repeated under the same time duration , for example in (0-1hr) load duration the load would be (51000-(13000+28000))=10000, (13000+28000) being subtracted from the total load as the same is already considered under (1minute -1hr )load. 2.3. The cell sizing data that will be useful in filling out the cell sizing work sheet is derived from the duty cycle diagram and tabulated as below : Cell sizing data --------------------------------------------------------------------------------period Loads Total Amperes Duration (min) ---------------------------------------------------------------------------------. 2.4. 1. L1+L2+L3+L4 983 1 2. L1+L2+L3+L5+L6 359 59 3. L1+L2+L6 127 60 4. L1 13 480 -------------------------------------------------------------------------------Capacity rating factors (KT) are derived from the table for HDP, Type II tubular lead acid cells enclosed in Appendix-2. (These can be read from the curves enclosed in Appendix-2 also).. 2.5. Sh.29 &30 shows the way in which the cell sizing work sheet and the KT rating factor would be used to size the battery for the duty cycle indicated.. 2.6. Design margin Considered as 1.0 since the loads for 210 MW thermal power plant are well established.. 2.7. Temperature correction factor : Minimum ambient temperature for the installation is 7deg.C. Hence, the lowest expected electrolyte temperature to be considered (in accordance with cl.5.2.3) is 17deg.C (=7deg.C+10deg.C) Temperature correction factor to be applied 0.43 (27-17) = 1 + ----100 = 1.043. ISSUE R3 FORM NO. 120 R1.

(33) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-3 SHEET. 28. OF 79. PART – A : LEAD ACID BATTERY. NOTES : 1.. Tubular cell type HDP-II is considered in the above sample calculation as the duty requires the cells to deliver high discharge in short duration (1 hr). However, the same procedure as above can be followed for sizing the battery using HDP Type-I or standard discharge performance cells. Data on cell capacities at varying periods of discharge for standard discharge performance type cells & for Type-I HDP cells is enclosed in Appendix-2.. 2.. If plante cells are being sized, the data on capacities for Type II HDP cells enclosed in Appendix-2 can be used sizing procedure also remains same except the value of 'K' in formula for temperature correction factor (Refer cl.5.2.3).. 3.. Typical DC emergency loads for a 210 MW unit are considered for the sample calculation above. In case the load cycle diagram for a particular installation happens to be more complex than the one in the sample calculation above, IEEE 485-1273 may be referred for further guidance.. ISSUE R3 FORM NO. 120 R1.

(34) SECTION: APPENDIX-3. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 29. OF 79. PART – A : LEAD ACID BATTERY. Project :. Date :. Lowest Expected Electrolyte Temp : 17oC. (1). Period. (2). Load (Ampe res). Minimum 1 Min.:1.75V DC Cell Voltage : Others: 1.85V DC. Cell Chloride Mfg. : India. Cell Tubular Type : HDP, Type-II Sized By : RRN. (3). (4). (5). (6). (7). Change in Load (Amperes). Duration of Period (minutes). Time to End of Section (minutes). Capacity at T Min. rate K Factor (KT). Required Section Size or (3)x(6B) = Rated AH. Pos Values. Neg.Value. LOAD DATA : A1= 983 A, M1= 1 Min; A2 = 359 A, A3= 127 A, M3= 60 Min; A4 = 13 A, A5= A, M5= Min; A6 = A, M6 = Min.. M2 = 59 Min. M4 = 480 Min.. Section - 1: First Period only - If A2 is greater than A1, go to Section-2 1 A1=983 A1-0=983 M1=1 T=M1=1 Sec.-1. Section - 2: First Two Periods only - If A3 is greater than A2, go to Section-3 1 A1=983 A1-0=983 M1=1 T=M1+M2=60 2 A2=359 A2-A1= -624 M2=59 T=M2=59 Sec.-2. Section - 3: First Three Periods only - If A4 is greater than A3, go to Section-4 1 A1=983 A1-0=983 M1=1 T=M1+...+M3=120 2 A2=359 A2-A1= -624 M2=59 T=M2+M3=119 3 A3=127 A3-A2= -232 M3=60 T=M3=60 Sec.-3. Section - 4: First Four Periods only - If A5 is greater than A4 go to Section-5 1 A1=983 A1-0=983 M1=1 T=M1+...+M4=600 2 A2=359 A2-A1= -624 M2=59 T=M2+...+M4=599 3 A3=127 A3-A2= -232 M3=60 T=M3+M4=540 4 A4=13 A4-A3= -134 M4=480 T=M4=480 Sec.-4. Section - 5: First Five Periods only - If A6 is greater than A4 go to Section-6 1 A1= A1-0= M1= T=M1+...+M5= 2 A2= A2-A1= M2= T=M2+...+M5= 3 A3= A3-A2= M3= T=M3+...+M5= 4 A4= A4-A3= M4= T=M4+M5= 5 A5= A5-A4= M5= T=M5= Sec.-5. 0.76 Total. 747 747. 2.55 2.55 Sub Total Total. 2507. 3.35 3.35 2.55 Sub Total Total. 3293. 10 10 9.1 8.2 Sub Total Total. 9830. 2507 916. 3293 611. 9830 544. Sub Total Total. *** ***. 1591 1591 ***. 2090 592 2682 ***. 6240 2111 935 9286 ***. ***. Section - 6: IF LOAD CYCLE HAS MORE THAN 5 LOAD PERIODS, CONTINUE FURTHER IN SIMILAR MANNER.. ISSUE R3 FORM NO. 120 R1.

(35) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-3 SHEET. 30. OF 79. PART – A : LEAD ACID BATTERY. Section - 7: Random Equipment Load only (if needed) R AR= AR-0= MR=. T=M+R=. Section - 8: Maximum Section Size = 916. Section - 9: Random Section Size = -. Section - 10: Temperature Correction Factor = 1.043. Section - 11: Design margin = 1.0. Section - 12: Aging Factor = 1.25. Section - 13: Uncorrected size = (8) + (9)= 916+ - = 916. Section - 14: All capacity required = (13) x (10) x (11) x (12) = 916 x 1.043 x 1.0 x 1.25 = 1193 AH. Section - 15: When AH capacity required is larger than the nearest standard cell, the next larger size cell is required.. Section - 16: Therefore AH capacity of the cell = 1200 AH. ISSUE R3 FORM NO. 120 R1.

(36) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-4 SHEET. 31. OF 79. PART – A : LEAD ACID BATTERY. TYPICAL BATTERY ROOM LAYOUT. FOR DETAILS REFER HARDCOPY. ISSUE R3 FORM NO. 120 R1.

(37) SECTION: APPENDIX-4. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 32. OF 79. PART – A : LEAD ACID BATTERY. Project :. Date :. Lowest Expected Minimum Electrolyte Temp : oC Cell Voltage :. Cell. Cell. Mfg. :. Type :. Sized By :. (1). (2). (3). (4). (5). (6). Period. Load (Amperes). Change in Load (Amperes). Duration of Period (minutes). Time to End of Section (minutes). Capacity at T Min. rate K Factor (KT). (7) Required Section Size or (3)x(6B) = Rated AH. Pos Values. Neg.Value. LOAD DATA : A1= A3= A5=. A, A, A,. M1= M3= M5=. Min; Min; Min;. A2 = A4 = A6 =. A, A, A,. M2 = M4 = M6 =. Min. Min. Min.. Section - 1: First Period only - If A2 is greater than A1, go to Section-2 1 A1= A1-0= M1= T=M1= Sec.-1. Section - 2: First Two Periods only - If A3 is greater than A2, go to Section-3 1 A1= A1-0= M1= T=M1+M2= 2 A2= A2-A1= M2= T=M2= Sec.-2. Section - 3: First Three Periods only - If A4 is greater than A3, go to Section-4 1 A1= A1-0= M1= T=M1+...+M3= 2 A2= A2-A1= M2= T=M2+M3= 3 A3= A3A2= M3= T=M3= Sec.-3. Section - 4: First Four 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+...+M4= 3 A3= A3-A2= M3= T=M3+M4= 4 A4= A4-A3= M4= T=M4= Sec.-4. Total. *** ***. Sub Total Total. ***. Sub Total Total. ***. Sub Total Total. ***. Sub Total Total. ***. Section - 5: First Five Periods only - If A6 is greater than A4 go to Section-6 1 A1= A1-0= M1= T=M1+...+M5= 2 3 4 5. A2= A3= A4= A5=. A2-A1= A3-A2= A4-A3= A5-A4=. M2= M3= M4= M5=. T=M2+...+M5= T=M3+...+M5= T=M4+M5= T=M5= Sec.-5. ISSUE R3 FORM NO. 120 R1.

(38) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-4 SHEET. 33. OF 79. PART – A : LEAD ACID BATTERY. Section - 6: IF LOAD CYCLE HAS MORE THAN 5 LOAD PERIODS, CONTINUE FURTHER IN SIMILAR MANNER.. Section - 7: Random Equipment Load only (if needed) R AR= AR-0= MR=. T=M+R=. Section - 8: Maximum Section Size =. Section - 9: Random Section Size =. Section - 10: Temperature Correction Factor =. Section - 11: Design margin =. Section - 12: Aging Factor =. Section - 13: Uncorrected size = (8) + (9)=. Section - 14: All capacity required = (13) x (10) x (11) x (12). Section - 15: When AH capacity required is larger than the nearest standard cell, the next larger size cell is required.. Section - 16: Therefore AH capacity of the cell = AH. ISSUE R3 FORM NO. 120 R1.

(39) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: FACING SHEET SHEET. 34. OF 79. PART – B : NICAD BATTERY. PART-B NICAD BATTERY. ISSUE R3 FORM NO. 120 R1.

(40) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 35. OF 79. PART – B : NICAD BATTERY. 1.0. SCOPE This section outlines the Ni-Cd alkaline station storage battery performance characteristics, usage and sizing.. 2.0. DIFFERENT TYPES OF Ni-Cd BATTERIES. 2.1. The most common electrode design for the nickel-cadmium batteries is the pocket plate type designated by 'P' as per IS:10918-1274. The active constituents are cadmium in the negative plates and nickel in the positive plates. The active material in each electrode is enclosed in metal pockets of finely perforated steel strips. Each plate is insulated from the next by thin plastic separators. The electrolyte is a solution of potassium hydroxide in de-ionised water. The resulting electrochemical reaction produces a nominal discharge voltage of 1.2 volts per cell. The electrolyte takes no part in these reactions and acts only as an ion conductor. The other electrode designs are sintered plate(s) and tubular plate(T).. 2.2. The cells are further classified as H,M,L and X type based on the discharge performance of individual designs. The plate type, and the number of such plates employed in a cell indicate the cell type and determine its discharge characteristics.. 2.3. The cell container is usually translucent polypropelene plastic.Polypropelene has high strength, it is corrosion free and not electrically conductive. Cells can also be supplied in stainless steel containers, if required, to with-stand conditions of high shock and vibrations. Steel cells are mounted on wooden racks.. 3.0. PERFORMANCE CHARACTERISTICS. 3.1. The rated capacity C5 of any cell type is defined as available amperehours (Ah) at 5 hours discharge rate at 27°C, to an end voltage of 1.0V/Cell after charging for 8 hours with 0.2C5 A. (In the U.S. the Ni-Cd capacity is based on 8 hours discharge). The standard ambient temp. specified by IS:10918 is 27°C, whereas the Ni-Cd batteries available in Indian market are rated at 20°C +5°C ambient. The same is adopted in the design guide for the present.. 3.2. Normal voltage is 1.2V/Cell ISSUE R3 FORM NO. 120 R1.

(41) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SECTION: WRITEUP SHEET. DC SYSTEM. 36. OF 79. PART – B : NICAD BATTERY. 3.3. Open circuit voltage is 1.28 V/Cell.. 3.4. The measure of performance is not the rated Ah capacity but the battery cell construction. H type cells have thin plates (more plate area per amount of active material) giving excellent high rate performance. M and L types have medium thickness plates and thick plates respectively. For example H-type cell at 15 minutes discharge can deliver about twice the discharge current compared to an L-type cell of equal rated capacity.. 3.5. The published discharge data for nickel-cadmium cells are most commonly available in tabular form, in which the current, available from each cell type, is stated for a given discharge time and end of discharge voltage. For intermediate times and voltages, it is necessary to interpolate between the known values (IEEE 11151992).. 3.6. There are three manufacturers in India, AMCO (in collaboration with SAFT,France), SABNIFE POWER SYSTEMS LTD., Hyderabad in collaboration with M/s Sabnife, Sweden and Punjab Power Packs Ltd. in collaboration with M/s Alcad Ltd. UK. The available tabulated discharge performance data from M/s SABNIFE on different types of cells for varying end cell voltages, is enclosed at Appendix-1.(The cell designations of Sabnife make cells confirm to IS.S10918-1274). More details if required, may be obtained from the manufacturers.. 3.7. EFFECT OF TEMPERATURE Battery optimum performance is based on cell electrolyte temperature maintained at 20°-25°C. For temperatures below 20°C a loss of about 0.5% of rated capacity per °C is expected for Ni-Cd battery. No increase in capacity is to be considered above 20°C. The derating curves enclosed in Appendix-1 can be used for arriving at the derating factors appropriate to the lowest expected electrolyte temperature for the individual installation. Example: Cell Type Cell end Volt Discharge time Min. Ambient temperature Lowest expected electrolyte temp.. : KPM100P : 1.1 V : 30 mins : 0°C : 0+10°C ( Ref. Clause 5.2.3 ISSUE R3 FORM NO. 120 R1.

(42) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SECTION: WRITEUP SHEET. DC SYSTEM. 37. OF 79. PART – B : NICAD BATTERY. of Part – A of this design guide ) : 0.925. Temp. derating factor (From enclosed curves) Available current at 10°C = 101A. (Data from performance table at 20-25°C) x 0.925 = 93.425A. 3.7.1. Life of the battery is shortened when temperatures are above the reference temperature of 25°C. Generally it has been estimated that Ni-Cd battery loses approximately 15% of its life for every 8°-10°C electrolyte temperature above 25°C.. 3.8. CHARGING REQUIREMENTS To fully charge, a cell will require an Ah input, from the charger to the battery, of 160% of the capacity. For example a 100Ah cell requires 160 Ah to fully charge it from a fully discharged state. If the charger can supply 20A then the time for charging will be 160/20 i.e. 8 hours.. 3.9. Cell Data : Type-L. Type-M. Type-H. a) D C internal resistance, ohms. 0.20x(1/C5) 0.15x(1/C5) 0.06x(1/C5). b) Maximum Short circuit current, A. 10xC5. 15xC5. 25xC5. 3.10. The electrolyte specific gravity (S.G.) is not an indication of the state of charge in Ni-Cd cells since it does not change appreciably during charge or discharge. The acceptable limits to be maintained in normal service (of the electrolyte S.G) are 1.17-1.19 at a reference temperature of 20° at the specified level line of the cell.. 3.11. Indian Standard 10918-1274 specifies the general requirements and methods of test for Ni-Cd batteries. This is derived from IEC Pub 6231978.. 4.0. APPLICATIONS OF Ni-Cd BATTERIES Some typical applications of different battery (Cell) types (X,H,M,L) are mentioned herewith for their optimum usage. Applications of very high rates of discharge batteries (Type X) are to deliver very large currents (>7C5) for very short durations (1 Sec-15 min).. 4.1. ISSUE R3 FORM NO. 120 R1.

(43) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 38. OF 79. PART – B : NICAD BATTERY. 4.2. Applications of High rate (H type) batteries are to deliver high currents (>3.5C5 A) for very short discharge times of 20 mins and less. Typical uses are - Engine starting (gen-sets, fire pumps, locomotives, vehicles) - Some applications of Uninterruptible power supply (UPS). - Switch closing, electromagnets. In such cases the capacity of the battery is not so important as the ability to deliver high current.. 4.3. Medium rate (M type) applications are load duties having discharge times between 3 hours to 30 min, for examples: - UPS for A.C process control - Electric train control - Off-shore applications - Combined discharge cycle like switchgear operation, standby pumps and emergency lighting.(Typically medium rate of discharge usage is between 0.5C5A and 3.5C5A).. 4.4. Low rate (L type) applications are of power requirements for an extended discharge time of 3 hours and longer. Example are:- Telecommunications and signalling - Scada/Computer system - General standby applications for power stations/ industrial projects, i.e. load cycle duty of switch trippings, emergency oil pumps, emergency lighting, protection/controls annunciation, communication. (Typically low rate of discharge usage is between less than 0.5C5A to C5A).. ISSUE R3 FORM NO. 120 R1.

(44) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 39. OF 79. PART – B : NICAD BATTERY. 4.5. For applications where adverse conditions of usage prevail, (like extremes of temperature, on regular routine maintenance and nonavailability of a separate battery room), Ni-Cd batteries are most suitable for use because of their following special features. a). Tolerance of extremes of temperature. The manufacturers claim the range from -50°C to +55°C. It is of advantage to use Ni-Cd battery for cold temperature performance.. b). Maintenance requirements are very low for pocket plate Ni-Cd batteries when operated as mentioned in clause 5.0 within the range of 15°C to 25°C.. c). Overcharging even for a prolonged period is tolerated. Also, these batteries can be left in discharged/partially discharged conditions without damage.. d). Gases given off by Ni-Cd batteries are not corrosive and normal building materials/room can be used and therefore the battery can be kept in the electrical/mechanical equipment room, if it becomes necessary to do so. However, adequate ventilation is necessary as stated under installation (Clause 7.0).. 5.0. MODE OF OPERATION. 5.1. In the standby battery usage for continuous parallel operation with rectifier, with occasional battery discharge, the recommended charging values are as follows: Charging in service: a). Float charge. :. 1.4 - 1.42 V/Cell H,M,L. b). High rate (Boost) charge. :. 1.53-1.67 V/Cell for H type 1.54-1.69 V/Cell for M type 1.55-1.7 V/Cell for L type. c). Trickle charging current of : fully charged cell. 1.5 mA per Ah. d). Boost charging standard. 0.4C5A for 8 hours,H,M,L. :. ISSUE R3 FORM NO. 120 R1.

(45) SECTION: WRITEUP. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 40. OF 79. PART – B : NICAD BATTERY. e). Fast recharging. :. 0.5C5A for 2.5 Hours followed by 0.2C5A for 2.5 hours.. f). With float charging at 1.4-1.42 V/Cell and where the load temporarily exceeds the charger rating, it is beneficial to apply an equalising charge every 6 to 12 months (depending on use) to keep the battery up to a fully charged condition.. 5.2. For use of batteries without any boost charge, the float charge voltage is 1.47-1.5V pC for L type, 1.46-1.49V pC for M type and 1.45-1.47V pC for H type.. 6.0. NUMBER OF CELLS For the usual standard system voltages, the recommended number of cells is as follows:. 6.1 Nominal System Voltage 24 No. of Cells For continuous operation with 19 float charging. 48. 110. 220. 37-38. 84-86. 168-172. 6.2. The number of cells to be used for a specific project should be checked considering the nominal system voltage, voltage tolerances, charging voltage (i.e. mode of operation) and type of load (i.e. discharge currents / time for given cell end - voltage). Based on these factors the number of cells may vary from the number given above.. 6.3. Recommendations on selection of voltage level and quantities of batteries cells are provided at Clause 3.0 & 4.0 of Part – A of this design guide.. 6.4. Example : a). Nominal system voltage 110V. b). All equipments are specified to operate satisfactorily at 80-110% of rated DC voltage, except the DC motors which work satisfactorily upto 85% of rated voltage.. ISSUE R3 FORM NO. 120 R1.

(46) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 41. OF 79. PART – B : NICAD BATTERY. c). No. of cells 'n' Allowable max. voltage for DC system = 110% of 110V = 121 volts Float voltage to be selected = 1.4 to 1.42 V/Cell With float voltage of 1.42 V pC and system voltage limit of 121 volts.. d). No. of cells required of 110V rated DC system 121 = ---- = 85.2 or 85 cells. 1.42 Cell end voltage : Allowable min. voltage for DC system 85% of 110V at equipment terminals = 93.5 volts. Considering a max. voltage drop of 5% in the system, Allowable min. voltage at battery terminals = 90% of 110V = 99 volts. 99 Thus permissible cell end voltage =---- = 1.16 volts 85. 7.0. OTHER CONSIDERATIONS FOR SIZING Ni-Cd BATTERIES In addition to the above factors, factors like design margin, ageing factor also influence the final size of the battery selected.. 7.1. Design Margin : This is to allow for unforeseen additions to the dc systems and less than optimum operating conditions of the battery due to improper maintenance, recent discharge or ambient temperatures lower than anticipated. This shall be decided on case to case basis. The cell size calculations for a specific application will seldom match a commercially available cell exactly and it is normal procedure to select the next higher size cell. The additional capacity obtained thus, can be considered part of the design margin. While sizing battery for ISSUE R3 FORM NO. 120 R1.

(47) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 42. OF 79. PART – B : NICAD BATTERY. Nuclear power plant applications, it may be noted that the "margins" required by IEEE Std. 323-1273, 6.3.1.5 and 6.3.3 are to be applied during "qualification" and are not related to "design margin". 7.2. Ageing Factor : Capacity decreases gradually during the life of the battery, with no sudden capacity loss being encountered. Since the rate of capacity loss is dependent upon such factors as operating temperature, electrolyte sp.gravity, and depth and frequency of discharge, an ageing factor should be chosen based on required service life. The choice of ageing factor is, therefore, essentially an economic consideration. IEEE recommends a factor of 1.11 for batteries used for UPS wherein the discharges are for a short time and 1.43 for applications involving continuous high temperatures and/or frequent deep discharges.. 7.3. State of Charge Factor : When the batteries are subjected to discharge and then charge, they get charged gradually. The state of charge at any point depends on the initial state of charge, the recharge voltage, the charge current limit and the charging voltage. The state of charge factor can be determined by consulting the charging curves provided by Battery manufacturers and shall be considered if the selected float charge voltage is 1.47-1.50V (Ref. item 5.2 above).. 7.4. Float Charge Factor : When batteries are expected to remain in continuous float charge for prolonged periods without boost charge, they exhibit a dip in performance depending on end voltage and duration of discharge. The cells float charged at 1.4-1.42V pC (Ref item 5.1 of above) are not expected to lose much charge if the schedule for equalising charges is adhered to. Hence no provision is made for float charge factor in cell sizing calculations.. 8.0. INSTALLATION. 8.1. Ni-Cd battery can be installed in a separate room or in the same room as the electrical/mechanical equipment since the gases given off are not corrosive. However, a separate room specially for large size ISSUE R3 FORM NO. 120 R1.

(48) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 43. OF 79. PART – B : NICAD BATTERY. batteries would be preferable. The typical battery room layout is enclosed in Part – A of this design guide for information. 8.2. Though Ni-Cd batteries are tolerant of extremes of temperature, it is preferable to operate within the range of 15°C to 25°C to optimise efficiency. Direct sunlight and heat on cells should be avoided.. 8.3. Hydrogen and oxygen evolved from a battery during charge can form an explosive mixture. For this reason adequate ventilation is to be provided to keep the hydrogen content to a low value. The maximum gas evolution occurs at end of charge or on overcharge. Since hydrogen is lighter than air, openings/grilles to take away the gas mixture should be located as high as possible in the room. Following formula is given by the Manufacturers for a mean hydrogen concentration of 1%. Air changes required per hour. =. 1.47xFinal charge(amps)xNo. of cells Room air Vol.in Cu.ft. If forced ventilation is found necessary to obtain the required air changes per hour, the air should be drawn from a high location in the room. When calculating air changes in confined spaces it will be necessary to deduct the volume of other apparatus and the battery. 9.0. BATTERY SIZING CALCULATIONS The method to be used for sizing Ni-Cd battery is same as explained in PART–A of this DC System Design guide .. 9.1. The duty cycle profile (the load currents and the durations for which the battery is to be sized) shall be prepared.. 9.2. The factor KT related to the specified end cell voltage and load duration is readily available for lead-acid cells. But for Ni-Cd cells, this shall be computed from the discharge data tables (enclosed at Appendix-1). Wherever the required data is not available, it can be interpolated/extrapolated from the known values (Refer item 3.5 above). Select the cell type most suited to the duty profile required (Ref. item 4.0).. 9.3. Add 10°°C to the min. ambient temperature specified to obtain expected minimum electrolyte temperature and read the temperature ISSUE R3 FORM NO. 120 R1.

(49) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 44. OF 79. PART – B : NICAD BATTERY. correction factors corresponding to the cell type selected and specific discharge duration, for the above temp, from the relevant curves enclosed in Appendix-1. 9.4. Divide the load currents specified by the temperature correction factors corresponding to the specified duration to obtain the load currents corrected to 25°C.. 9.5. Select the cell size, looking at the discharge tables, that can meet the short duration load current requirements.. 9.6. Crated Calculate the capacity rating factors ( KT = ------- ; t = duration ) It for different load currents & corresponding durations as above, from the discharge tables.. 9.7. Follow the worksheet (Blank form enclosed in Appendix-3) and determine the cell size. Apply ageing factor, design margin etc. (in accordance with item 7.0 above) to arrive at final cell size.. 9.8. Sample cell sizing calculation is included in Appendix-2.. 10.0. SPECIFYING THE BATTERY It is observed that the discharge data available from different manufacturers for a given type and AH rating of cells differs considerably at durations other than nominal duration (5 hours). Hence it is recommended that while specifying the battery, the following may be noted.. 10.1. Load profile, required end cell voltage, factors to be considered and other data shall be provided to the bidder and the bidder is allowed to offer cell size other than the one indicated (determined by TCE through cell sizing calculations as above) providing the supporting calculations.. 10.2. Bidder may be allowed to offer cell type other than the one indicated, if the offered cell type & size meets the load cycle duty requirements satisfactorily (bidder to establish the same through supporting calculations). This is being recommended as many a time the load profile consists of mixed type of loads (ie. of different durations) and thus more than one type (but with different ratings) can meet the ISSUE R3 FORM NO. 120 R1.

(50) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: WRITEUP SHEET. 45. OF 79. PART – B : NICAD BATTERY. requirements satisfactorily. 11.0. REFERENCES. 11.1. TCE.M6-EL-718-6000 'Station battery- Lead Acid' Design Guide.. 11.2. IS:10918-1274 Specification for vented type Ni-Cd batteries.. 11.3. Technical Data from M/s SABNIFE.. 11.4. IEEE 1115-1992 IEEE Recommended Practice for sizing NickelCadmium Batteries for Stationary applications.. 11.5. IEEE : 1106-1277 IEEE Recommended practice for maintenance, testing and replacement of Nickel-Cadmium storage batteries for Generating Stations and Substations.. 11.6. IEEE : 323-1273 IEEE Standard for qualifying class IE equipment for Nuclear Power Generating Stations.. ISSUE R3 FORM NO. 120 R1.

(51) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-1 SHEET. 46. OF 79. PART – B : NICAD BATTERY. APPENDIX-1 CELL DESIGNATION Vented nickel cadmium prismatic rechargeable cells shall be designated by the letter 'K' followed by a second letter referring to the positive plates: T for cells with tubular plates, P for cells with pocket plates, and S for cells with sintered plates. The second letter shall be followed by a third letter: L for low rate of discharge (below 0.5 C5), M for medium rate of discharge (between 0.5 C5 and 3.5 C5), H for high rate of discharge (between 3.5 C5 and 7 C5), and X for very high rate of discharge (above 7 C5). The group of three letters shall then be followed by a group of figures indicative of the capacity of the cell in ampere-hours, for example KSH 185. Cells in cases of plastic material shall be marked with the letter "p" after the figures, for example KSH 185 P. Source : IS:10918-1274. ISSUE R3 FORM NO. 120 R1.

(52) TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. DC SYSTEM. SECTION: APPENDIX-1 SHEET. 47. OF 79. PART – B : NICAD BATTERY. APPENDIX-1 (contd) PREFERRED DIMENSIONS TABLE :. THESE DIMENSIONS ARE VALID FOR OPEN NICKEL CADMIUM PRISMATIC CELLS IN STEEL CONTAINERS AND PLASTIC CONTAINERS. STEEL CONTAINERS PLASTIC CONTAINERS Max. Width. (b)in Max. Height (h) in Max. Width. (b) Max. Height (h) in mm mm mm in mm 81 291 62 178 105 350 81 241 131 409 87 273 148 409 123 273 157 409 138 273 188 409 147 285 --165 406 --173 375 --195 406 NOTE 1 --. The dimensions, given in Table 1, represent preferred values.. NOTE 2 --. The widths relate to the overall width dimension of the cell excluding the thickness of the lug flanges.. NOTE 3 --. The maximum height relates to the total height dimensions over terminals or closed cell valves. The data for heights given in table are maximum values, no lower limits being stated.. NOTE 4 --. It is not possible to make proposals for length dimensions (d) at this stage.. NOTE 5 --. The dimensions shown in Table 1 are not coupled to particular cell capacities. The apply to all kinds of open prismatic nickelcadmium cells, such as L,M,H, and X types.. Source : IS:10918-1274. ISSUE R3 FORM NO. 120 R1.

(53) SECTION: APPENDIX-1. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. 48. SHEET. DC SYSTEM. OF 79. PART – B : NICAD BATTERY. KPL RANGE TYPICAL CELL PERFORMANCE DATA ( 20o C + 5o C ) Discharge data is for full charged cells after 1 hour open circuit and allowing for voltage losses associated with connectors.. AMPERES ON DISCHARGE TO 1.00 VOLT PER CELL. CELL TYPE. CAP (Ah). SECONDS. MINUTES. HOURS. 1. 10. 60. 5. 10. 30. 60. 90. 2. 3. 5. 8. 10. KPL5P KPL11P KPL19P KPL29P KPL39P KPL49P KPL60P KPL70P KPL75P KPL90P KPL100P KPL130P KPL155P KPL190 KPL220P KPL250P KPL280P KPL320P KPL350P KPL380P KPL410P KPL440P KPL480P KPL500P. 5 11 19 29 39 49 60 70 75 90 100 130 155 190 220 250 280 320 350 380 410 440 480 500. 11.8 25.9 44.7 68.3 93.6 120 138 157 177 204 231 283 337 389 440 486 531 579 628 675 723 750 805 916. 9.7 21.4 37 56.5 76.8 96.6 115 131 150 171 193 236 282 327 373 413 453 496 539 581 624 654 713 808. 8 17.7 30.5 46.6 62.9 80 96.5 111 118 137 156 192 213 258 308 346 377 409 442 473 505 570 615 676. 6.6 14.5 25 38.1 51.3 67.7 81.8 90.5 94.9 108 123 150 182 230 244 274 300 326 351 378 406 483 525 566. 5.9 12.9 22.3 34 45.5 59.8 72.5 79.4 82.8 93.1 105 131 158 186 214 241 265 290 315 339 363 443 482 514. 4.6 10 17 26.7 35.9 45.1 55.2 61.7 65 74.8 85.7 108 124 147 172 197 222 246 271 296 321 368 400 428. 3.5 7.7 13.3 20.3 27.3 34.3 42 48.3 51.7 61. 71.4 89.6 107 129 150 171 193 215 236 258 279 297 323 352. 2.8 6.2 10.6 16.2 21.8 27.4 33.6 38.6 42 49.5 57.1 71.7 87.9 106 124 141 159 177 194 212 230 243 254 278. 2.3 5 8.6 13.1 17.6 22.1 27 31.1 34.2 40.1 45.9 57.6 70.7 85.1 99.5 113 128 142 156 171 185 199 216 227. 1.6 3.5 6.1 9.3 12.5 15.7 19.2 22.1 24.3 28.5 32.6 41 50.2 60.5 70.7 80.6 90.9 101 111 121 132 141 154 162. 1 2.2 3.8 5.8 7.8 9.8 12 14 15 18 20 26 31 38 44 50 56 64 70 76 82 88 95 100. 0.6 1.4 2.4 3.7 4.9 6.2 7.6 8.7 9.5 11.2 12.9 15.1 19.8 23.8 27.8 31.8 35.8 39.8 43.7 47.8 51.8 55.4 61.2 64.4. 0.5 1.1 1.9 2.9 3.9 4.9 6.1 7 7.7 9 10.3 12.9 15.9 19.1 22.3 25.3 28.7 31.9 35 38.3 41.5 45.5 49.4 52. KPL580P KPL655P KPL730P KPL810P KPL885P KPL960P KPL1100P KPL1210P KPL1320P KPL1440P. 580 655 730 810 885 960 1100 1210 1320 1440. 1030 1150 1270 1390 1500 1610 1900 2080 2250 2410. 914 1020 1120 1230 1330 1420 1690 1840 1992 2140. 768 860 955 1050 1140 1230 1430 1570 1710 1840. 644 722 801 880 966 1050 1200 1320 1450 1570. 596 678 743 808 886 964 1090 1210 1330 1440. 490 552 612 672 736 800 912 1010 1100 1190. 400 448 494 540 594 646 729 810 891 969. 319 360 402 446 487 528 605 666 726 792. 261 295 329 365 398 432 495 545 594 648. 186 210 234 259 283 307 352 387 422 461. 116 131 146 162 177 192 220 242 254 288. 74 83.5 93.1 103 113 122 140 154 168 184. 59.7 67.5 75.2 83.4 91.2 98.9 113 125 136 148. ISSUE R3 FORM NO. 120 R1.

(54) SECTION: APPENDIX-1. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 49. OF 79. PART – B : NICAD BATTERY. KPL RANGE TYPICAL CELL PERFORMANCE DATA ( 20o C + 5o C ) Discharge data is for full charged cells after 1 hour open circuit and allowing for voltage losses associated with connectors.. AMPERES ON DISCHARGE TO 1.02 VOLT PER CELL. CELL TYPE. CAP (Ah). 1. 10. 60. 5. 10. 30. 60. 90. 2. 3. 5. 8. 10. KPL5P KPL11P KPL19P KPL29P KPL39P KPL49P KPL60P KPL70P KPL75P KPL90P KPL100P KPL130P KPL155P KPL190 KPL220P KPL250P KPL280P KPL320P KPL350P KPL380P KPL410P KPL440P KPL480P KPL500P. 5 11 19 29 39 49 60 70 75 90 100 130 155 190 220 250 280 320 350 380 410 440 480 500. 11.1 24.4 42.2 64.3 88 113 130 147 167 192 218 267 318 367 415 453 500 546 592 637 683 706 757 875. 9.2 20.2 34.9 53.3 72.2 91 108 124 140 160 181 222 264 307 350 388 425 463 502 540 578 628 674 762. 7.5 16.6 28.7 43.8 58.9 75.2 90.5 104 112 128 145 182 215 251 288 322 351 383 414 445 476 537 579 638. 6.2 13.5 23.4 35.7 48.4 63.5 76.7 84.8 88.9 101 115 139 169 198 227 255 279 304 331 354 380 452 491 532. 5.5 12.1 20.9 32 43.4 56.5 68.1 74.4 77.5 86.9 98.6 122 147 173 199 224 247 272 298 321 344 416 452 482. 4.4 9.7 16.6 25.7 34.8 43.9 53.5 59.4 62.4 71.3 81.8 102 119 142 165 188 211 235 259 282 306 351 381 406. 3.4 7.5 13 19.8 26.7 33.5 41 47.2 49.9 58.7 68.1 85.5 103 123 144 164 185 206 227 247 268 286 311 337. 2.7 6 10.4 15.9 21.4 26.9 32.9 37.8 41 48.2 55.5 69.6 85.4 103 120 137 154 172 189 206 224 237 258 271. 2.2 7.9 8.4 12.9 17.3 21.8 26.6 30.6 33.7 39.5 45.3 56.8 69.7 83.9 98.1 112 126 140 154 168 182 196 213 223. 1.6 3.5 6 9.2 12.4 15.5 19 21.9 24.1 28.2 32.3 40.6 49.7 59.9 70 79.8 90 100 110 120 130 139 151 159. 1 2.2 3.8 5.7 7.7 9.7 11.9 13.9 14.8 17.8 19.8 25.7 30.7 37.6 43.6 49.5 55.4 63.4 69.3 75.2 81.2 87.1 95 99. .6 1.4 2.4 3.6 4.9 6.1 7.5 8.6 9.5 11.1 12.8 16 19.7 23.7 27.7 31.6 35.5 39.5 43.4 47.5 51.5 56.5 60.9 64.1. 0.50 1.1 1.9 2.9 3.9 4.9 6 6.9 7.6 8.9 10.2 12.9 15.8 19 22.2 25.3 28.5 31.7 34.8 38.1 41.3 45.3 49.2 51.8. KPL580P KPL655P KPL730P KPL810P KPL885P KPL960P KPL1100P KPL1210P KPL1320P KPL1440P. 580 655 730 810 885 960 1100 1210 1320 1440. 979 1086 1198 1310 1412 1514 1792 1960 2118 2266. 862 964 1060 1162 1254 1344 1594 1740 1883 2020. 724 810 899 988 1073 1158 1346 1478 1610 1735. 603 675 750 826 904 982 1124 1236 1354 1470. 554 627 693 760 832 904 1030 1138 1246 1352. 462 519 581 642 702 759 872 963 1050 1134. 382 426 474 522 576 621 709 784 859 932. 311 349 391 435 474 513 591 649 708 771. 257 290 323 359 391 424 487 536 584 638. 183 206 230 255 279 302 347 381 416 454. 115 130 145 160 175 190 218 240 261 285. 73.5 83.1 92.5 103 112 122 140 154 163 183. 59.5 67.1 74.8 83 90.7 98.4 113 124 135 143. SECONDS. MINUTES. HOURS. ISSUE R3 FORM NO. 120 R1.

(55) SECTION: APPENDIX-1. TATA CONSULTING ENGINEERS TCE.M6-EL-7186000. SHEET. DC SYSTEM. 50. OF 79. PART – B : NICAD BATTERY. KPL RANGE TYPICAL CELL PERFORMANCE DATA ( 20o C + 5o C ) Discharge data is for full charged cells after 1 hour open circuit and allowing for voltage losses associated with connectors.. AMPERES ON DISCHARGE TO 1.02 VOLT PER CELL. CELL TYPE. CAP (Ah). 1. 10. 60. 5. 10. 30. 60. 90. 2. 3. 5. 8. 10. KPL5P KPL11P KPL19P KPL29P KPL39P KPL49P KPL60P KPL70P KPL75P KPL90P KPL100P KPL130P KPL155P KPL190 KPL220P KPL250P KPL280P KPL320P KPL350P KPL380P KPL410P KPL440P KPL480P KPL500P. 5 11 19 29 39 49 60 70 75 90 100 130 155 190 220 250 280 320 350 380 410 440 480 500. 11.1 24.4 42.2 64.3 88 113 130 147 167 192 218 267 318 367 415 453 500 546 592 637 683 706 757 875. 9.2 20.2 34.9 53.3 72.2 91 108 124 140 160 181 222 264 307 350 388 425 463 502 540 578 628 674 762. 7.5 16.6 28.7 43.8 58.9 75.2 90.5 104 112 128 145 182 215 251 288 322 351 383 414 445 476 537 579 638. 6.2 13.5 23.4 35.7 48.4 63.5 76.7 84.8 88.9 101 115 139 169 198 227 255 279 304 331 354 380 452 491 532. 5.5 12.1 20.9 32 43.4 56.5 68.1 74.4 77.5 86.9 98.6 122 147 173 199 224 247 272 298 321 344 416 452 482. 4.4 9.7 16.6 25.7 34.8 43.9 53.5 59.4 62.4 71.3 81.8 102 119 142 165 188 211 235 259 282 306 351 381 406. 3.4 7.5 13 19.8 26.7 33.5 41 47.2 49.9 58.7 68.1 85.5 103 123 144 164 185 206 227 247 268 286 311 337. 2.7 6 10.4 15.9 21.4 26.9 32.9 37.8 41 48.2 55.5 69.6 85.4 103 120 137 154 172 189 206 224 237 258 271. 2.2 7.9 8.4 12.9 17.3 21.8 26.6 30.6 33.7 39.5 45.3 56.8 69.7 83.9 98.1 112 126 140 154 168 182 196 213 223. 1.6 3.5 6 9.2 12.4 15.5 19 21.9 24.1 28.2 32.3 40.6 49.7 59.9 70 79.8 90 100 110 120 130 139 151 159. 1 2.2 3.8 5.7 7.7 9.7 11.9 13.9 14.8 17.8 19.8 25.7 30.7 37.6 43.6 49.5 55.4 63.4 69.3 75.2 81.2 87.1 95 99. .6 1.4 2.4 3.6 4.9 6.1 7.5 8.6 9.5 11.1 12.8 16 19.7 23.7 27.7 31.6 35.5 39.5 43.4 47.5 51.5 56.5 60.9 64.1. 0.50 1.1 1.9 2.9 3.9 4.9 6 6.9 7.6 8.9 10.2 12.9 15.8 19 22.2 25.3 28.5 31.7 34.8 38.1 41.3 45.3 49.2 51.8. KPL580P KPL655P KPL730P KPL810P KPL885P KPL960P KPL1100P KPL1210P KPL1320P KPL1440P. 580 655 730 810 885 960 1100 1210 1320 1440. 979 1086 1198 1310 1412 1514 1792 1960 2118 2266. 862 964 1060 1162 1254 1344 1594 1740 1883 2020. 724 810 899 988 1073 1158 1346 1478 1610 1735. 603 675 750 826 904 982 1124 1236 1354 1470. 554 627 693 760 832 904 1030 1138 1246 1352. 462 519 581 642 702 759 872 963 1050 1134. 382 426 474 522 576 621 709 784 859 932. 311 349 391 435 474 513 591 649 708 771. 257 290 323 359 391 424 487 536 584 638. 183 206 230 255 279 302 347 381 416 454. 115 130 145 160 175 190 218 240 261 285. 73.5 83.1 92.5 103 112 122 140 154 163 183. 59.5 67.1 74.8 83 90.7 98.4 113 124 135 143. SECONDS. MINUTES. HOURS. ISSUE R3 FORM NO. 120 R1.

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