battery sizing design basis tce

8/18/2019 Battery Sizing Design Basis TCE

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TATA CONSULTING ENGINEERSSECTION: TITLE

TCE.M6-EL-718-6000 DC SYSTEM

SHEET ( ) OF (v)

REV.NO R1 R2 R3 ISSUE

INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN

PPD.BY CPS Sd/- RRN Sd/- RRN Sd/- R3

CKD.BY DKB/DDRC Sd/- VS Sd/- VS Sd/-

APP.BY DKB Sd/- UAK Sd/- UAK Sd/-

DATE 92-09-04 97-03-31 99-03-02

i

FORM NO. 020R2

DESIGN GUIDE

FOR

DC SYSTEM

TATA CONSULTING ENGINEERS

73/1, ST. MARK’S ROAD

BANGALORE 560 001

FLOPPY NO : TCE.M6-EL-FP-DOC-006

FILE NAME : M6-6000.DWG


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TATA CONSULTING ENGINEERSSECTION:REV. STATUS


SHEET ( ) OF (v)ii

ISSUE

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FORM NO. 120 R1

REVISION STATUS

REV. NO DATE DESCRIPTION

R3 99-03-02

1.Design guides for Lead Acidbattery-(M6-EL-BT-6000 R2),NiCad

battery (M6-EL-BT-6000A R1) andbattery Chargers(M6-EL-BC-6004

R2) have been combined to make acomposite design guide on the ‘DCSystem’.

2. In addition the loads consideredfor emergency lighting , auxiliaryrelays and indicating lamps have

been revised.

3.Section 4.0 providing

recommendation for quantities of batteries in different installations hasbeen revised.


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TATA CONSULTING ENGINEERSSECTION:CONTENTS


SHEET ( ) OF (v)iii

FORM NO. 120 R1

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CONTENTSPART-A

LEAD ACID BATTERY

SL.NO. TITLE SHEET NO.

1.0 SCOPE 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 HDPTUBULAR 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


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TATA CONSULTING ENGINEERSSECTION:CONTENTS


SHEET ( ) OF (v)v

FORM NO. 120 R1

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R3

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 BOOSTCHARGER WITH TCE.M2-EL-CW-S-2631 R0

2 x 100% BATTERIES

ii) FLOAT CUM BOOSTCHARGER WITH TCE.M2-EL-CW-S-2632 R0

1 x 100% BATTERY

iii) FLOAT AND BOOST

CHARGER WITH TCE.M2-EL-CW-S-2633 R01 x 100% BATTERY


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TATA CONSULTING ENGINEERSSECTION:Facing Sheet


PART – A : LEAD ACID BATTERY

SHEET OF 791

FORM NO. 120 R1

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PART-ALEAD ACID BATTERY


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TATA CONSULTING ENGINEERSSECTION:WRITEUP



SHEET OF 792

FORM NO. 120 R1

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1.0 SCOPE

This design guide outlines the recommendation for the determinationof voltage level, capacity, quantities and installation of DC battery of

lead acid storage type required for providing DC power supply toessential 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 NickelCadmium 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 yearslonger than that for tubular type. However, the plante type battery iscostlier 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) High Discharge Performance (HDP)

b) Maintenance Free-Valve Regulated (MF-VR)c) Low-Maintenance (LM) type

2.4 The capacity of HDP cells under short duration discharge conditionsare higher than that of normal tubular batteries and are comparable tothat 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


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SHEET OF 793

FORM NO. 120 R1

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the plants where organised maintenance is infrequent. The lowmaintenance cells have grids made of low-antimony lead and requiretopping 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 whereorganised maintenance is infrequent or standalone substations in thedistribution 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 between2.16 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 maximumboost 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 :

a) Quantum of power

b) Individual load point power ratings, quantum of such load pointsand the geographic spread of the load points

c) Standard voltages suitable for the equipment

3.2 For the same power requirement, the battery room size, and batterycost 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 limitscable sizes will be higher than those with higher voltage. Consideringall the aspects following voltage levels are recommended.


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SHEET OF 794

FORM NO. 120 R1

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3.2.1 Power Plant3.2.1.1 Large power plants (Coal based)

a) For electrical power, - 220 V DCcontrol & protectionrequirements

b) I&C system Normally most of the I&Cvendors' systems are suitable

for +24V or 48V DC.Thevoltage level shall be fixed

after I&C system requirementis finalised.

c) Isolated auxiliary plants - 30 V DC or 110 V DC like raw

water pump house (dedicatedbattery if running lengths of cables from the main plant iscomparatively much higher)

d) Switchyards - 220 V DC (If switchyard hasgot 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 plantsincluding captive power plants

3.2.2 Industrial Plants

a) Large plants with many - 220 V DC

load points and distributed in large area

b) Small plants with - 110 V DC multiple load points and outdoor substations

c) Small plants with very - 30 V DC few switchboards / load points

d) For process control - Generally 24/48V (Asrequired by the I&C system

design)


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SHEET OF 795

FORM NO. 120 R1

ISSUE

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4.0 QUANTITIES OF BATTERIES4.1 Power Plants4.1.1 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. Theunit and common services batteries shall be sized to cater oneunit 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 additionswitchyard DCDB will be provided with a tie feeder from stationDCDB (as a standby).

d) One no. 100% rating battery shall be considered for coalhandling plant DC power requirements.

4.1.2 For large power units (500 MW and above) and nuclear power plants,

for each unit, the 220V DC unit loads shall be divided into twocategories, 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, safety-

supervisory systems etc.

Each category of loads will be catered to by a separate 220V battery

and battery charger system. There will be three 50% ratedbatteries.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 willcater power loads and the third one will be catering control loads.

For switchyard load there will be a seperate 100% battery feedingswitchyard 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.


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SHEET OF 796

FORM NO. 120 R1

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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 tohave each unit battrery rated to cater two gas turbine units.and a tiefeeder 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 berecommended.

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-AU-G-715-6011 for UPS.

4.2 Industrial Plants and Small Power PlantsTwo 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 loadpoints and their geographic location.

A separate battery may be required for instrumentation, control andannunciation requirement for process purposes. The specificrequirements 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 samestation 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.


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SHEET OF 797

FORM NO. 120 R1

ISSUE

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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 Vper 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) Duty cycle

b) End of the duty cycle voltagec) Temperature correction factor

d) Compensation for ageinge) Design margin

5.2.1 Duty cycle

a) At the time of power supply failure, the battery is required tosupply D.C. power requirements of essential circuits for safe

shut down of the station, vital instrumentation, controls,

communication system, DC annunciation and emergencylighting.

b) In power plants and some industrial plants an emergency dieselgenerator is available, which will provide a.c. power to the

battery charger after the period required to start and connect itto the emergency AC bus. However, the battery size shall becalculated 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 isdifferent. The same may be continuous or for short time durationor 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 Loads (Amperes)

i) Upto 1 minute * Trip relay / Trip coil currents of

circuit breakers.


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SHEET OF 798

FORM NO. 120 R1

ISSUE

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* Starting currents of allautomatically started D.C.motors.

* DC motor operated emergencysteam stop valves.

* Solenoid valves for isolation,safety relief, minimum

recirculation etc.

* Inrush currents of supervisorysafety system for fuel, turbineand 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 * Indicating lamps / Semaphoreindicators in switchgears/control

panels* Control room emergency lighting* Annunciation (10%)

• Auxiliary relay ( which are likely

to be energized during black out

condition )

d) A table of loads indicating their power requirement and durationshall be prepared and a load curve for the battery shall beestablished. 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 thatproject specific loads for DC motors, T.G. & S.G. vendor loads

and inrush currents shall be obtained before proceeding with thesizing.


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SHEET OF 799

FORM NO. 120 R1

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e) I&C battery for power plant application shall be sized to cater the loads for half hour. The loads to be considered shall be themaximum load of I&C system at any operating condition viz

starting, running and tripping/stopping.

5.2.2 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 bewithstood by D.C. equipment. The D.C. equipment are generally

rated to operate between +10% and -15% of their rated valuewith certain exceptions like trip coils and trip relays which canaccept lower voltages.

b) Manufacturers recommend a float voltage ranging from 2.06V to2.3 volts per cell, for different float voltage adopted, the requiredfrequency of equalising charges are given below.------------------------------------------------------------------------------------

Float Voltage Per Cell Approximateperiodicity ofequalising 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) Considering the above, the number cells of a battery areselected as :

Max.allowable DC voltage - Regulation due to charger ---------------------------------------------------------------

Float voltage per cell

ii) The end of duty cycle cell voltage is determined


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SHEET OF 7910

FORM NO. 120 R1

ISSUE

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by

Min. allowable D.C. voltage + Cable drop

-------------------------------------------------No. of cells

d) Typical values for 220V DC system and 24V DC systems aregiven in the table below:

Sl.No

System Max.allowablevoltage

Min.allowablevoltage

No.of cells

End of duty cyclevoltage

1 220V 242V 187V 108 1 min - 1.75V /cell 1,2 HRS &

10 hours -1.85V/cell

2 24V 30V* 21.5V* 13 1.8V/cell

* To be ascertained on project to project basisNote : For 110V & 30V plant DC systems, the details can be worked

out in the same manner as for 220V system above.

e) The cable drop to be considered in DC system shall be 2% fromthe charger/battery to Distribution board and 3% from board toany feeder in case of 220V DC system.

f) In case of 24V DC system to keep the voltage dropwithin 5% limit, the cable sizes between DC board and I&Ccabinets are very large and sometimes impractical to terminate.

Hence for 24V system a total drop of 7.5% (2.5% between boardand charger/battery and 5% between board and individualloads) is recommended.

5.2.3 Temperature correction factor

The standard temperature for stating cell capacity is 27deg.C. If thelowest expected electrolyte temperature is below 27deg.C, a celllarge enough to have the required capacity available at the lowest

expected temperature shall be selected. The lowest electrolytetemperature shall be considered as 10

o above minimum ambient

temperature. If the lowest expected temperature is above 27deg.C,

no correction factor shall be applied. The correction factor shall becalculated according to the formula:


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SHEET OF 7911

FORM NO. 120 R1

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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. Theminimum 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 afactor 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 batterysizing for tender specification purposes and/or the battery sizing is

being done for a similar plant already executed, no design margin isconsidered 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 havehigher capacity factor than the tubular standard discharge

performance cell. Hence for power plant application and for applications where short duration loads are appreciable highdischarge performance cell shall be used.

The capacity of the battery shall then be determined in accordancewith the procedure outlined in Appendix-3.


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SHEET OF 7912

FORM NO. 120 R1

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6.0 INSTALLATION

6.1 Battery cells shall be installed in a separate battery room, preferablynear 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 guideTCE.M6-EL-PJ-G-SG-6602 R1 (GA of Turbine Building ElectricalEquipment & 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 andbody.

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, specificrequirements shall be obtained from the battery manufacturer.

6.6 Separate cable(s) shall be provided for each polarity of the outgoingbattery 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-traysthrough 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 gasis generated. The volume of hydrogen gas generated depends on the

amount of charging current. Also, the float current demand of a fullycharged battery will double approximately for every 10deg.C riseabove 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. Hydrogenexplosive concentration is reached if the explosives mixture is three

percent of the volume of room air.


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SHEET OF 7913

FORM NO. 120 R1

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6.9 In view of the presence of hydrogen gas, warning signs shall beinstalled outside and inside the room prohibiting smoking, sparks of flame.

6.10 Lighting fixtures shall be vapour-proof type with reflectors paintedwith 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-acidtype with Plante' positive platesSpecification.

7.3 IEEE Std 485-1273 : Recommended practice for sizing large leadacid storage batteries for GeneratingStations and Sub-stations.

7.4 IS:8320-1272 : General requirements and methods of testsfor lead-acid storage batteries

7.5 IS:1885-1965 : Electrotechnical vocabulary -Secondary cells and batteries.

7.6 IEEE Std. 450-1270 : Recommended practice for maintenancetesting and replacement of large lead

storage batteries for generating stations andsub-stations.

7.7 IEEE Std. 484-1271 : Recommended practice for Installationdesign and installation of large lead storagebatteries for generating stations and sub-

stations.

7.8 IEEE Std. 323-1273 : IEEE Standard for Qualifying class-1E

Equipment for Nuclear Power GeneratingStations.


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TATA CONSULTING ENGINEERSSECTION:

APPENDIX - 1



SHEET 14 OF 79

FORM NO. 120 R1

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APPENDIX-1

TYPICAL EMERGENCY LOADS

STEAM TG500MW 120MW 210MW

1 a) Bearing oil pump 13kW 15kW 13kWb) Bearing oil pump for BFPT 2x5.5kW --- ---c) Bearing oil pump for MBFP 11kW --- ---

2 a) Seal oil pump 13kW 10kW 11kWb) Seal water pump for BFPS 60kW --- ---

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)

9 Auxiliary contactor (each)

10 DC emergency lights

11 UPS load (Incl. DAS,transmitters, controllers)

55kVA 45KVA 30kVA

.


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APPENDIX - 1



SHEET 15 OF 79

FORM NO. 120 R1

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APPENDIX-1 (Cont’d)

TYPICAL EMERGENCY LOADS

STEAM TG500MW 120MW 210MW

Continuous Loads

1 Annunciator window (each) ß---------------------5W -----------------à

2 Indicating lamp (each) ß -----5-10W For filament type ----àß ----1 W For cluster LED type type ---à

3 Auxiliary relays (each)


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APPENDIX-2



SHEET OF 7916

FORM NO. 120 R1

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APPENDIX-2

CELL DATA

RATING AND DESIGNATION

1 Ampere-Hour Rating

The rating assigned to the cell shall be the capacity expressed inampere-hours (after correction to 27deg.C) stated by themanufacturer to be obtainable when the cell is discharged at the 10-

hour rate (C10) to a final voltage of 1.85 voltage.

2. Designation

The cell shall be designated by symbols given below, arranged in thefollowing sequence :

Type of Positive Ah Rating Type of Plate of Cell Container (See 2.1) (See 2.2) (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 beingstandardized 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 thecapacity in Ah.

2.3 The material of container shall be designated by any one of thefollowing letters as the case may be :

G - for glass;H - for hard-rubber;

P - for plastics;


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APPENDIX-2



SHEET OF 7917

FORM NO. 120 R1

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W - for wood, lead-lined; or F - for fibre reinforced plastics (FRP)

Example : T 400H HDP - designates a high discharge performancecell having tubular positive plates and a capacity of 400 Ah at 10 hour

rate in hard-rubber container. SOURCE : IS 1651 & 1652 - 1991


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APPENDIX-2



SHEET OF 7918

FORM NO. 120 R1

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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 beinterchanged.

2. In the case of batteries with built-in cell connectors, the height of

the interconnector shall be disregarded.


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APPENDIX-2



SHEET OF 7919

FORM NO. 120 R1

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3. For capacities not covered in this table, the cell dimensions shallnot 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 CellHours (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 1.783 0.717 4.18 1.804 0.782 5.12 1.81

5 0.833 6.00 1.826 0.879 6.83 1.837 0.917 7.63 1.83

8 0.950 8.42 1.849 0.979 9.19 1.8410 1.0 10 1.85

--------------------------------------------------------------------------------------------

Source : IS 1651-1991


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APPENDIX-2



SHEET OF 7920

FORM NO. 120 R1

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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

0.60 1.67 1.75

1 0.488 2.05 1.80 } M/s Chloride 0.392 2.55 1.85 } India

0.738 2.71 1.78 2 0.714 2.80 1.80 } M/s Chloride

0.597 3.35 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, 5hour and 10 hours (ISS does not specify capacities at other discharge rates for Type-I cells).


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APPENDIX-2



SHEET OF 7921

FORM NO. 120 R1

ISSUE

R3

TYPICAL CELL PERFORMANCE CURVES (SH-1)


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APPENDIX-2



SHEET OF 7922

FORM NO. 120 R1

ISSUE

R3


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APPENDIX-2



SHEET OF 7923

FORM NO. 120 R1

ISSUE

R3

APPENDIX - 2 (Cont’d)

CELL DATA

Capacities and Dimensions: Plante Cells

-----------------------------------------------------------------------------------

Capacity at Maximum Overall Dimensions10-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 beinterchanged.

2. For capacities not covered in this table, the cell dimensions shallnot exceed the dimensions of the cell of next higher size covered

by this table.

Source : IS 1652-1995


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APPENDIX-3



SHEET OF 7924

FORM NO. 120 R1

ISSUE

R3

BATTERY DUTY CYCLE DIAGRAM

L1 = 13 A

L2 = 30A

L3 = 46A

L

4

=

9

0

0

A

L5 = 186 A

L6 = 84 A

1 60120 600

SECTION-1

SECTION-2

SECTION-3

SECTION - 4

DURATION ( MIN )


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APPENDIX-3



SHEET OF 7925

FORM NO. 120 R1

ISSUE

R3

APPENDIX - 3

SAMPLE CALCULATION FOR SIZING OF A THERMAL POWERSTATION 220V UNIT BATTERY (210 MW)

LOAD TABULATION

Sl.no

Load description Qty. RatingWatts

1 min 1 hr. 2hrs. 10 hrs.

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* - 11,000

c. Jacking oil pump 1 28,000 70,000* 28,000

d. Others 2,000 2,000

3 Steam generator

DC CSP (includes

FSSS, mill panel)

10,000 - 10,000

4. Main steam stopvalve

2 4,000 10,000

5. Scanner air fan 1 7,500 18,750 * - 7,500

6. Emergency lighting - - 5000 1000

7. Indicating lamps 400 1 # 400

8. Annunciation

windows

10 5 100 50

9. Auxiliary relays LS LS 600 (200nos @ 3Weach )


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APPENDIX-3



SHEET OF 7926

FORM NO. 120 R1

ISSUE

R3

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 # 500

3. PA system LS LS 2,000

4. Auxiliary relays LS LS 300(100 nos

@3Weach )

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 :

Sl.

noDuration Load

In Watts in Amperes

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 = 6500W30A

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

NOTE: These loads are arrived at taking care to see that loads are not


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APPENDIX-3



SHEET OF 7927

FORM NO. 120 R1

ISSUE

R3

repeated under the same time duration , for example in (0-1hr) loadduration 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)

---------------------------------------------------------------------------------

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 --------------------------------------------------------------------------------

2.4 Capacity rating factors (KT) are derived from the table for HDP, TypeII tubular lead acid cells enclosed in Appendix-2. (These can be readfrom the curves enclosed in Appendix-2 also).

2.5 Sh.29 &30 shows the way in which the cell sizing work sheet and theKT 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 plantare 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 (inaccordance 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


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APPENDIX-3



SHEET OF 7928

FORM NO. 120 R1

ISSUE

R3

NOTES :

1. Tubular cell type HDP-II is considered in the above samplecalculation as the duty requires the cells to deliver high discharge in

short duration (1 hr). However, the same procedure as above can befollowed for sizing the battery using HDP Type-I or standarddischarge 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 alsoremains 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 aparticular installation happens to be more complex than the one in thesample calculation above, IEEE 485-1273 may be referred for further guidance.


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APPENDIX-3



SHEET OF 7929

FORM NO. 120 R1

ISSUE

R3

Project : Date :Lowest Expected Minimum 1 Min.:1.75V DC Cell Chloride Cell Tubular Electrolyte Temp : 17oC Cell Voltage : Others: 1.85V DC Mfg. : India Type : HDP, Type-II Sized By : RRN

(1)

Period

(2)

Load

(Ampe

res)

(3)

Change in

Load

(Amperes)

(4)

Duration

of Period

(minutes)

(5)

Time to

End of

Section

(minutes)

(6)

Capacity

at T Min.

rate

K Factor

(K T)

(7)

Required Section Size or

(3)x(6B) = Rated AH

Pos Values Neg.Value

LOAD DATA :A1= 983 A, M1= 1 Min; A2 = 359 A, M2 = 59 Min.

A3= 127 A, M3= 60 Min; A4 = 13 A, M4 = 480 Min.

A5= A, M5= Min; A6 = A, M6 = 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 0.76 747 ***

Sec.-1 Total 747 ***

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 2.55 2507

2 A2=359 A2-A1= -624 M2=59 T=M2=59 2.55 1591

Sec.-2 Sub Total 2507 1591

Total 916 ***

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 3.35 3293

2 A2=359 A2-A1= -624 M2=59 T=M2+M3=119 3.35 2090

3 A3=127 A3-A2= -232 M3=60 T=M3=60 2.55 592


Total 611 ***

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 10 9830

2 A2=359 A2-A1= -624 M2=59 T=M2+...+M4=599 10 6240

3 A3=127 A3-A2= -232 M3=60 T=M3+M4=540 9.1 2111

4 A4=13 A4-A3= -134 M4=480 T=M4=480 8.2 935


Total 544 ***

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 Sub Total

Total ***

Section - 6: IF LOAD CYCLE HAS MORE THAN 5 LOAD PERIODS, CONTINUE FURTHER IN SIMILAR MANNER.


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APPENDIX-3



SHEET OF 7930

FORM NO. 120 R1

ISSUE

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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


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APPENDIX-4



SHEET 31 OF 79

FORM NO. 120 R1

ISSUE

R3

TYPICAL BATTERY ROOM LAYOUT

FOR DETAILS REFER HARDCOPY


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APPENDIX-4



SHEET 32 OF 79

FORM NO. 120 R1

ISSUE

R3

Project : Date :

Lowest Expected Minimum Cell Cell

Electrolyte Temp : oCCell Voltage : Mfg. : Type : Sized By :

(1)

Period

(2)

Load

(Amperes)

(3)

Change in

Load

(Amperes)

(4)

Duration

of Period

(minutes)

(5)

Time to

End of

Section

(minutes)

(6)

Capacity

at T Min.

rate

K Factor

(K T)

(7)

Required Section Size or

(3)x(6B) = Rated AH

Pos Values Neg.Value

LOAD DATA :A1= A, M1= Min; A2 = A, M2 = Min.

A3= A, M3= Min; A4 = A, M4 = Min.

A5= A, M5= Min; A6 = A, M6 = 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 Total ***

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 Sub TotalTotal ***

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 Sub Total

Total ***

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 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 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 Sub Total

Total ***


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APPENDIX-4



SHEET 33 OF 79

FORM NO. 120 R1

ISSUE

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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


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TATA CONSULTING ENGINEERSSECTION:FACING SHEET


PART – B : NICAD BATTERY

SHEET 34 OF 79

FORM NO. 120 R1

ISSUE

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PART-B

NICAD BATTERY


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SHEET 35 OF 79

FORM NO. 120 R1

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1.0 SCOPE

This section outlines the Ni-Cd alkaline station storage batteryperformance 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. Theactive constituents are cadmium in the negative plates and nickel inthe positive plates. The active material in each electrode is enclosed

in metal pockets of finely perforated steel strips. Each plate isinsulated from the next by thin plastic separators. The electrolyte is asolution of potassium hydroxide in de-ionised water. The resultingelectrochemical reaction produces a nominal discharge voltage of 1.2

volts per cell. The electrolyte takes no part in these reactions andacts only as an ion conductor. The other electrode designs aresintered plate(s) and tubular plate(T).

2.2 The cells are further classified as H,M,L and X type based on thedischarge performance of individual designs. The plate type, and the

number of such plates employed in a cell indicate the cell type anddetermine its discharge characteristics.

2.3 The cell container is usually translucent polypropeleneplastic.Polypropelene has high strength, it is corrosion free and notelectrically conductive. Cells can also be supplied in stainless steel

containers, if required, to with-stand conditions of high shock andvibrations. Steel cells are mounted on wooden racks.

3.0 PERFORMANCE CHARACTERISTICS

3.1 The rated capacity C5 of any cell type is defined as availableamperehours (Ah) at 5 hours discharge rate at 27°C, to an endvoltage 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°Cambient. The same is adopted in the design guide for the present.

3.2 Normal voltage is 1.2V/Cell


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SHEET 37 OF 79

FORM NO. 120 R1

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of Part – A of this design guide ) Temp. derating factor : 0.925 (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 thebattery, 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, 0.20x(1/C5) 0.15x(1/C5) 0.06x(1/C5) ohms

b) Maximum Short circuit 10xC5 15xC5 25xC5 current, A

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 duringcharge or discharge. The acceptable limits to be maintained in normalservice (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 andmethods of test for Ni-Cd batteries. This is derived from IEC Pub 623-

1978.

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. 4.1 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).


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SHEET 38 OF 79

FORM NO. 120 R1

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4.2 Applications of High rate (H type) batteries are to deliver highcurrents (>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 theability to deliver high current.

4.3 Medium rate (M type) applications are load duties having dischargetimes 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, standbypumps and emergency lighting.(Typically medium rate of dischargeusage is between 0.5C5 A and 3.5C5 A).

4.4 Low rate (L type) applications are of power requirements for anextended 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 0.5C5 A toC5 A).


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SHEET 39 OF 79

FORM NO. 120 R1

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4.5 For applications where adverse conditions of usage prevail, (likeextremes of temperature, on regular routine maintenance and non-availability 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-Cdbatteries 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 dischargedconditions without damage.

d) Gases given off by Ni-Cd batteries are not corrosive and normalbuilding materials/room can be used and therefore the battery

can be kept in the electrical/mechanical equipment room, if itbecomes 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 recommendedcharging values are as follows:

Charging in service:

a) Float charge : 1.4 - 1.42 V/Cell H,M,L

b) High rate (Boost) : 1.53-1.67 V/Cell for H typecharge

1.54-1.69 V/Cell for M type 1.55-1.7 V/Cell for L type

c) Trickle charging current of : 1.5 mA per Ahfully charged cell

d) Boost charging standard : 0.4C5 A for 8 hours,H,M,L


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SHEET 40 OF 79

FORM NO. 120 R1

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e) Fast recharging : 0.5C5 A for 2.5 Hours followedby 0.2C5 A for 2.5 hours.

f) With float charging at 1.4-1.42 V/Cell and where the loadtemporarily exceeds the charger rating, it is beneficial toapply 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 and1.45-1.47V 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 48 110 220

No. of CellsFor continuous operation with

float charging

19 37-38 84-86 168-172

6.2 The number of cells to be used for a specific project should bechecked 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 thesefactors 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 thisdesign 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 worksatisfactorily upto 85% of rated voltage.


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SHEET 41 OF 79

FORM NO. 120 R1

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c) No. of cells 'n'

Allowable max. voltage for DC system = 110% of 110V = 121

voltsFloat voltage to be selected = 1.4 to 1.42 V/Cell

With float voltage of 1.42 V pC and system voltage limit of 121volts.

No. of cells required of 110V rated DC system 121

= ---- = 85.2 or 85 cells. 1.42

d) 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 = 99volts.

99Thus 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, ageingfactor 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 lessthan 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 cellsize calculations for a specific application will seldom match acommercially 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


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SHEET 42 OF 79

FORM NO. 120 R1

ISSUE

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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 appliedduring "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 capacityloss 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 economicconsideration. 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 frequentdeep 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 onthe initial state of charge, the recharge voltage, the charge currentlimit and the charging voltage. The state of charge factor can be

determined by consulting the charging curves provided by Batterymanufacturers and shall be considered if the selected float chargevoltage 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 inperformance depending on end voltage and duration of discharge.

The cells float charged at 1.4-1.42V pC (Ref item 5.1 of above) arenot expected to lose much charge if the schedule for equalising

charges is adhered to. Hence no provision is made for float chargefactor in cell sizing calculations.

8.0 INSTALLATION

8.1 Ni-Cd battery can be installed in a separate room or in the same roomas the electrical/mechanical equipment since the gases given off are

not corrosive. However, a separate room specially for large size


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batteries would be preferable. The typical battery room layout isenclosed 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 optimiseefficiency. Direct sunlight and heat on cells should be avoided.

8.3 Hydrogen and oxygen evolved from a battery during charge can forman explosive mixture. For this reason adequate ventilation is to beprovided 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 gasmixture should be located as high as possible in the room.

Following formula is given by the Manufacturers for a mean hydrogenconcentration of 1%.

Air changes required = 1.47xFinal charge(amps)xNo. of cellsper hour 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 benecessary 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 explainedin PART–A of this DC System Design guide .

9.1 The duty cycle profile (the load currents and the durations for whichthe battery is to be sized) shall be prepared.

9.2 The factor KT related to the specified end cell voltage and loadduration 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 beinterpolated/extrapolated from the known values (Refer item 3.5above).

Select the cell type most suited to the duty profile required (Ref. item4.0).

9.3 Add 10°°C to the min. ambient temperature specified to obtain

expected minimum electrolyte temperature and read the temperature


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SHEET 45 OF 79

FORM NO. 120 R1

ISSUE

R3

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 Nickel-

Cadmium 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.


51/85


APPENDIX-1



SHEET OF 7946

FORM NO. 120 R1

ISSUE

R3

APPENDIX-1

CELL DESIGNATION

Vented nickel cadmium prismatic rechargeable cells shall be

designated by the letter 'K' followed by a second letter referring to thepositive plates:

T for cells with tubular plates,P for cells with pocket plates, andS 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), andX for very high rate of discharge (above 7 C5).

The group of three letters shall then be followed by a group of figuresindicative of the capacity of the cell in ampere-hours, for example

KSH 185. Cells in cases of plastic material shall be marked with theletter "p" after the figures, for example KSH 185 P.

Source : IS:10918-1274


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APPENDIX-1



SHEET OF 7947

FORM NO. 120 R1

ISSUE

R3

APPENDIX-1 (contd)

PREFERRED DIMENSIONS

TABLE : THESE DIMENSIONS ARE VALID FOR OPEN NICKELCADMIUM PRISMATIC CELLS IN STEEL CONTAINERS ANDPLASTIC CONTAINERS

STEEL CONTAINERS PLASTIC CONTAINERS

Max. Width. (b)inmm Max. Height (h) inmm Max. Width. (b)in

mm

Max. Height (h) inmm

81

105131148

157188--

--

--

291

350409409

409409--

--

--

62

8187123

138147165

173

195

178

241273273

273285406

375

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 intable are maximum values, no lower limits being stated.

NOTE 4 -- It is not possible to make proposals for length dimensions (d) atthis stage.

NOTE 5 -- The dimensions shown in Table 1 are not coupled to particular cell capacities. The apply to all kinds of open prismatic nickel-cadmium cells, such as L,M,H, and X types.

Source : IS:10918-1274


53/85


APPENDIX-1



SHEET OF 7948

FORM NO. 120 R1

ISSUE

R3

KPL RANGE

TYPICAL CELL PERFORMANCE DATA ( 20o C + 5

o 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 10KPL5P 5 11.8 9.7 8 6.6 5.9 4.6 3.5 2.8 2.3 1.6 1 0.6 0.5

KPL11P 11 25.9 21.4 17.7 14.5 12.9 10 7.7 6.2 5 3.5 2.2 1.4 1.1

KPL19P 19 44.7 37 30.5 25 22.3 17 13.3 10.6 8.6 6.1 3.8 2.4 1.9KPL29P 29 68.3 56.5 46.6 38.1 34 26.7 20.3 16.2 13.1 9.3 5.8 3.7 2.9

KPL39P 39 93.6 76.8 62.9 51.3 45.5 35.9 27.3 21.8 17.6 12.5 7.8 4.9 3.9

KPL49P 49 120 96.6 80 67.7 59.8 45.1 34.3 27.4 22.1 15.7 9.8 6.2 4.9

KPL60P 60 138 115 96.5 81.8 72.5 55.2 42 33.6 27 19.2 12 7.6 6.1

KPL70P 70 157 131 111 90.5 79.4 61.7 48.3 38.6 31.1 22.1 14 8.7 7

KPL75P 75 177 150 118 94.9 82.8 65 51.7 42 34.2 24.3 15 9.5 7.7

KPL90P 90 204 171 137 108 93.1 74.8 61. 49.5 40.1 28.5 18 11.2 9

KPL100P 100 231 193 156 123 105 85.7 71.4 57.1 45.9 32.6 20 12.9 10.3

KPL130P 130 283 236 192 150 131 108 89.6 71.7 57.6 41 26 15.1 12.9

KPL155P 155 337 282 213 182 158 124 107 87.9 70.7 50.2 31 19.8 15.9

KPL190 190 389 327 258 230 186 147 129 106 85.1 60.5 38 23.8 19.1

KPL220P 220 440 373 308 244 214 172 150 124 99.5 70.7 44 27.8 22.3

KPL250P 250 486 413 346 274 241 197 171 141 113 80.6 50 31.8 25.3

KPL280P 280 531 453 377 300 265 222 193 159 128 90.9 56 35.8 28.7

KPL320P 320 579 496 409 326 290 246 215 177 142 101 64 39.8 31.9KPL350P 350 628 539 442 351 315 271 236 194 156 111 70 43.7 35

KPL380P 380 675 581 473 378 339 296 258 212 171 121 76 47.8 38.3

KPL410P 410 723 624 505 406 363 321 279 230 185 132 82 51.8 41.5

KPL440P 440 750 654 570 483 443 368 297 243 199 141 88 55.4 45.5

KPL480P 480 805 713 615 525 482 400 323 254 216 154 95 61.2 49.4

KPL500P 500 916 808 676 566 514 428 352 278 227 162 100 64.4 52

KPL580P 580 1030 914 768 644 596 490 400 319 261 186 116 74 59.7

KPL655P 655 1150 1020 860 722 678 552 448 360 295 210 131 83.5 67.5

KPL730P 730 1270 1120 955 801 743 612 494 402 329 234 146 93.1 75.2

KPL810P 810 1390 1230 1050 880 808 672 540 446 365 259 162 103 83.4

KPL885P 885 1500 1330 1140 966 886 736 594 487 398 283 177 113 91.2

KPL960P 960 1610 1420 1230 1050 964 800 646 528 432 307 192 122 98.9

KPL1100P 1100 1900 1690 1430 1200 1090 912 729 605 495 352 220 140 113

KPL1210P 1210 2080 1840 1570 1320 1210 1010 810 666 545 387 242 154 125KPL1320P 1320 2250 1992 1710 1450 1330 1100 891 726 594 422 254 168 136

KPL1440P 1440 2410 2140 1840 1570 1440 1190 969 792 648 461 288 184 148


54/85


APPENDIX-1



SHEET OF 7949

FORM NO. 120 R1

ISSUE

R3

KPL RANGE


o C )



CELL

TYPE

CAP


1 10 60 5 10 30 60 90 2 3 5 8 10KPL5P 5 11.1 9.2 7.5 6.2 5.5 4.4 3.4 2.7 2.2 1.6 1 .6 0.50

KPL11P 11 24.4 20.2 16.6 13.5 12.1 9.7 7.5 6 7.9 3.5 2.2 1.4 1.1

KPL19P 19 42.2 34.9 28.7 23.4 20.9 16.6 13 10.4 8.4 6 3.8 2.4 1.9

KPL29P 29 64.3 53.3 43.8 35.7 32 25.7 19.8 15.9 12.9 9.2 5.7 3.6 2.9

KPL39P 39 88 72.2 58.9 48.4 43.4 34.8 26.7 21.4 17.3 12.4 7.7 4.9 3.9

KPL49P 49 113 91 75.2 63.5 56.5 43.9 33.5 26.9 21.8 15.5 9.7 6.1 4.9

KPL60P 60 130 108 90.5 76.7 68.1 53.5 41 32.9 26.6 19 11.9 7.5 6

KPL70P 70 147 124 104 84.8 74.4 59.4 47.2 37.8 30.6 21.9 13.9 8.6 6.9

KPL75P 75 167 140 112 88.9 77.5 62.4 49.9 41 33.7 24.1 14.8 9.5 7.6

KPL90P 90 192 160 128 101 86.9 71.3 58.7 48.2 39.5 28.2 17.8 11.1 8.9

KPL100P 100 218 181 145 115 98.6 81.8 68.1 55.5 45.3 32.3 19.8 12.8 10.2

KPL130P 130 267 222 182 139 122 102 85.5 69.6 56.8 40.6 25.7 16 12.9

KPL155P 155 318 264 215 169 147 119 103 85.4 69.7 49.7 30.7 19.7 15.8

KPL190 190 367 307 251 198 173 142 123 103 83.9 59.9 37.6 23.7 19

KPL220P 220 415 350 288 227 199 165 144 120 98.1 70 43.6 27.7 22.2

KPL250P 250 453 388 322 255 224 188 164 137 112 79.8 49.5 31.6 25.3

KPL280P 280 500 425 351 279 247 211 185 154 126 90 55.4 35.5 28.5

KPL320P 320 546 463 383 304 272 235 206 172 140 100 63.4 39.5 31.7

KPL350P 350 592 502 414 331 298 259 227 189 154 110 69.3 43.4 34.8

KPL380P 380 637 540 445 354 321 282 247 206 168 120 75.2 47.5 38.1

KPL410P 410 683 578 476 380 344 306 268 224 182 130 81.2 51.5 41.3

KPL440P 440 706 628 537 452 416 351 286 237 196 139 87.1 56.5 45.3

KPL480P 480 757 674 579 491 452 381 311 258 213 151 95 60.9 49.2

KPL500P 500 875 762 638 532 482 406 337 271 223 159 99 64.1 51.8

KPL580P 580 979 862 724 603 554 462 382 311 257 183 115 73.5 59.5

KPL655P 655 1086 964 810 675 627 519 426 349 290 206 130 83.1 67.1

KPL730P 730 1198 1060 899 750 693 581 474 391 323 230 145 92.5 74.8

KPL810P 810 1310 1162 988 826 760 642 522 435 359 255 160 103 83

KPL885P 885 1412 1254 1073 904 832 702 576 474 391 279 175 112 90.7

KPL960P 960 1514 1344 1158 982 904 759 621 513 424 302 190 122 98.4

KPL1100P 1100 1792 1594 1346 1124 1030 872 709 591 487 347 218 140 113

KPL1210P 1210 1960 1740 1478 1236 1138 963 784 649 536 381 240 154 124

KPL1320P 1320 2118 1883 1610 1354 1246 1050 859 708 584 416 261 163 135

KPL1440P 1440 2266 2020 1735 1470 1352 1134 932 771 638 454 285 183 143


55/85


APPENDIX-1



SHEET OF 7950

FORM NO. 120 R1

ISSUE

R3

KPL RANGE


o C )



CELL

TYPE

CAP


1 10 60 5 10 30 60 90 2 3 5 8 10KPL5P 5 11.1 9.2 7.5 6.2 5.5 4.4 3.4 2.7 2.2 1.6 1 .6 0.50

KPL11P 11 24.4 20.2 16.6 13.5 12.1 9.7 7.5 6 7.9 3.5 2.2 1.4 1.1

KPL19P 19 42.2 34.9 28.7 23.4 20.9 16.6 13 10.4 8.4 6 3.8 2.4 1.9

KPL29P 29 64.3 53.3 43.8 35.7 32 25.7 19.8 15.9 12.9 9.2 5.7 3.6 2.9

KPL39P 39 88 72.2 58.9 48.4 43.4 34.8 26.7 21.4 17.3 12.4 7.7 4.9 3.9

KPL49P 49 113 91 75.2 63.5 56.5 43.9 33.5 26.9 21.8 15.5 9.7 6.1 4.9

KPL60P 60 130 108 90.5 76.7 68.1 53.5 41 32.9 26.6 19 11.9 7.5 6

KPL70P 70 147 124 104 84.8 74.4 59.4 47.2 37.8 30.6 21.9 13.9 8.6 6.9

KPL75P 75 167 140 112 88.9 77.5 62.4 49.9 41 33.7 24.1 14.8 9.5 7.6

KPL90P 90 192 160 128 101 86.9 71.3 58.7 48.2 39.5 28.2 17.8 11.1 8.9

KPL100P 100 218 181 145 115 98.6 81.8 68.1 55.5 45.3 32.3 19.8 12.8 10.2

KPL130P 130 267 222 182 139 122 102 85.5 69.6 56.8 40.6 25.7 16 12.9

KPL155P 155 318 264 215 169 147 119 103 85.4 69.7 49.7 30.7 19.7 15.8

KPL190 190 367 307 251 198 173 142 123 103 83.9 59.9 37.6 23.7 19

KPL220P 220 415 350 288 227 199 165 144 120 98.1 70 43.6 27.7 22.2

KPL250P 250 453 388 322 255 224 188 164 137 112 79.8 49.5 31.6 25.3

KPL280P 280 500 425 351 279 247 211 185 154 126 90 55.4 35.5 28.5

KPL320P 320 546 463 383 304 272 235 206 172 140 100 63.4 39.5 31.7

KPL350P 350 592 502 414 331 298 259 227 189 154 110 69.3 43.4 34.8

KPL380P 380 637 540 445 354 321 282 247 206 168 120 75.2 47.5 38.1

KPL410P 410 683 578 476 380 344 306 268 224 182 130 81.2 51.5 41.3

KPL440P 440 706 628 537 452 416 351 286 237 196 139 87.1 56.5 45.3

KPL480P 480 757 674 579 491 452 381 311 258 213 151 95 60.9 49.2

KPL500P 500 875 762 638 532 482 406 337 271 223 159 99 64.1 51.8

KPL580P 580 979 862 724 603 554 462 382 311 257 183 115 73.5 59.5

KPL655P 655 1086 964 810 675 627 519 426 349 290 206 130 83.1 67.1

KPL730P 730 1198 1060 899 750 693 581 474 391 323 230 145 92.5 74.8

KPL810P 810 1310 1162 988 826 760 642 522 435 359 255 160 103 83

KPL885P 885 1412 1254 1073 904 832 702 576 474 391 279 175 112 90.7

KPL960P 960 1514 1344 1158 982 904 759 621 513 424 302 190 122 98.4

KPL1100P 1100 1792 1594 1346 1124 1030 872 709 591 487 347 218 140 113

KPL1210P 1210 1960 1740 1478 1236 1138 963 784 649 536 381 240 154 124

KPL1320P 1320 2118 1883 1610 1354 1246 1050 859 708 584 416 261 163 135

KPL1440P 1440 2266 2020 1735 1470 1352 1134 932 771 638 454 285 183 143


56/85


APPENDIX-1



SHEET OF 7951

FORM NO. 120 R1

ISSUE

R3

KPL RANGE


o C )


AMPERES ON DISCHARGE TO 1.05V PER CELL

CELL CAP SECONDS MINUTES HOURS

TYPE AH 1 10 60 5 10 30 60 90 2 3 5 8 10

KPL5P 5 10.1 8.3 6.8 5.5 5 4.2 3.3 2.7 2.2 1.5 1 0.6 0.5

KPL11P 11 22.2 18.4 15 12.2 11 9.2 7.3 5.8 4.8 3.4 2.2 1.4 1.1

KPL19P 19 38.3 31.7 25.9 21 18.9 15.9 12.5 10.1 8.3 6.9 3.7 2.4 1.9KPL29P 29 58.4 48.4 39.5 32.1 28.9 24.3 19.1 15.4 12.6 9 5.7 3.6 2.9

KPL39P 39 79.6 65.4 52.8 44 40.2 33.1 25.7 20.7 17 12.2 7.6 4.8 3.9

KPL49P 49 102 82.7 67.9 57.3 51.5 42.2 32.3 26 21.3 15.3 9.5 6.1 4.9

KPL60P 60 118 97.9 81.5 69 61.5 51 39.6 31.8 26.1 18.7 11.8 7.4 6

KPL70P 70 133 113 94 76.1 66.9 56 45.5 36.6 30 20.5 13.7 8.6 6.9

KPL75P 75 151 125 102 79.6 69.6 58.5 47.1 39.5 33.1 23.7 14.7 9.4 7.6

KPL90P 90 175 143 114 90.2 77.7 66 55.2 46.3 38.7 27.8 17.6 11 8.9

KPL100P 100 199 162 129 102 89 76 63.2 53 44.4 31.7 19.6 12.5 10.1

KPL130P 130 244 201 166 123 108 94.5 79.4 66.6 55.7 39.9 25.5 15.9 12.7

KPL155P 155 289 238 193 149 130 112 97.3 81.6 68.3 49.8 30.4 19.5 15.6

KPL190 190 335 277 225 175 153 133 115 98.3 82.2 59.8 37.2 23.4 18.8

KPL220P 220 378 315 258 201 176 154 134 115 95.1 69 43.1 27.4 22

KPL250P 250 416 351 286 225 198 174 153 131 110 78.5 49 31.2 25.1KPL280P 280 453 382 313 248 220 195 173 148 124 88.5 54.9 35.2 28.3

KPL320P 320 496 414 343 271 245 217 193 164 137 98.6 62.7 39.2 31.4

KPL350P 350 539 447 373 301 272 242 213 180 151 108 68.6 43 34.5

KPL380P 380 581 478 403 317 294 262 232 197 165 113 74.5 47 37.7

KPL410P 410 624 510 432 342 316 284 251 214 179 123 80.4 51 40.9

KPL440P 440 640 573 487 406 375 325 270 228 191 149 86.2 55.8 45.1

KPL480P 480 685 615 526 440 407 352 292 248 208 152 94.1 60.6 48.9

KPL500P 500 814 692 580 480 434 373 314 262 217 160 98 63.7 51.5

KPL580P 580 902 786 658 542 492 420 354 300 250 183 114 73.2 59.1

KPL655P 655 990 880 736 604 550 470 394 333 282 207 128 82.7 56.8

KPL730P 730 1090 970 806 674 619 534 445 375 315 232 143 92.1 74.4

KPL810P 810 1190 1060 896 744 688 596 496 418 350 256 159 102 82.6KPL885P 885 1280 1140 974 812 750 650 540 455 380 281 173 112 90.2

KPL960P 960 1370 1230 1050 880 814 697 584 491 412 306 188 121 97.9

KPL1100P 1100 1630 1450 1220 1010 939 813 678 570 475 346 216 139 112

KPL1210P 1210 1780 1590 1340 1110 1030 894 744 625 523 383 237 153 123

KPL1320P 1320 1920 1720 1460 1210 1120 975 810 680 568 418 259 167 135

KPL1440P 1440 2050 1840 1580 1320 1220 1050 876 740 622 456 282 182 147


57/85


APPENDIX-1



SHEET OF 7952

FORM NO. 120 R1

ISSUE

R3

KPL RANGE


o C )




TYPE AH 1 10 60 5 10 30 60 90 2 3 5 8 10

KPL5P 5 8.3 6.9 5.6 4.6 4.4 3.8 3.2 2.6 2.1 1.5 1 0.5 0.5

KPL11P 11 18.4 15.2 12.3 10.1 9.6 8.4 6.9 5.6 4.6 3.4 2.1 1.3 1.1

KPL19P 19 31.7 26.3 21.3 17.5 16.1 13.5 11.5 9.5 8 5.8 3.7 2.3 1.9

KPL29P 29 48.4 40.2 32.5 26.7 25.3 22.2 18.3 14.8 12.2 8.9 5.6 3.5 2.8

KPL39P 39 65.1 53.8 43.6 36.3 35 30.4 24.5 19.9 16.4 12 7.5 4.8 3.8

KPL49P 49 82.6 68.1 55.1 47.3 45 39 31 25 20.6 15 9.5 5.9 4.8

KPL60P 60 97.4 81 66.6 57.3 54 46.5 37.5 30.6 25.2 18.4 11.6 7.3 5.9

KPL70P 70 111 93.3 76.6 61.9 58 50.6 41.7 35.2 29 21.2 13.5 8.4 6.8

KPL75P 75 128 106 81.2 64.2 60 52.5 43.8 36.1 30.4 22.3 14.5 9.3 7.4

KPL90P 90 147 119 94.7 71 66 58.8 50 42.3 35.6 26.7 17.4 10.9 8.7

KPL100P 100 166 135 106 82 75 66.9 57 48.5 40.8 30.8 19.3 12.4 10

KPL130P 130 202 166 130 99 92 83.1 71 60.8 51.2 38.4 25.1 15.5 12.5

KPL155P 155 240 199 158 117 110 101 87 74.6 62.8 47.1 29.9 19.2 15.4

KPL190 190 278 231 182 140 133 121 105 89.8 75.6 56.7 36.7 23.1 18.5

KPL220P 220 313 262 206 160 151 140 122 105 88.4 66.3 42.5 27 21.7

KPL250P 250 346 289 230 179 169 158 139 120 101 75.6 48.3 30.7 24.7

KPL280P 280 380 317 254 202 192 177 156 135 114 85.2 54.1 34.5 27.8

KPL320P 320 417 349 281 225 215 197 174 150 126 94.8 61.8 38.6 31

KPL350P 350 455 382 308 253 238 218 192 165 139 104 67.6 41.3 34

KPL380P 380 492 413 334 275 258 238 210 180 152 114 73.4 45.2 37.1

KPL410P 410 529 445 361 298 279 258 225 195 164 123 79.2 49.7 40.3

KPL440P 440 546 476 401 333 309 275 235 203 175 133 85 55.2 44.6

KPL480P 480 582 514 435 360 335 297 255 220 190 144 92.7 61 48.5

KPL500P 500 690 578 472 384 363 321 273 233 199 152 96.6 63.4 51

KPL580P 580 770 654 540 440 410 361 310 267 230 174 112 80 58.5

KPL655P 655 850 730 608 496 455 407 350 303 262 197 126 89 66.1

KPL730P 730 935 803 670 552 510 453 388 335 290 219 141 98 73.7

KPL810P 810 1020 876 732 608 565 506 430 370 320 243 156 109 81.8

KPL885P 885 1090 952 802 665 618 550 470 405 350 266 171 119 89.3

KPL960P 960 1160 1030 870 720 670 594 510 440 380 288 185 128 96.9

KPL1100P 1100 1400 1200 1000 828 765 680 582 503 435 338 212 149 111

KPL1210P 1210 1530 1310 1100 912 848 759 645 555 480 363 234 165 122

KPL1320P 1320 1640 1430 1200 990 927 825 705 608 525 395 255 179 133

KPL1440P 1440 1740 1540 1300 1080 1000 891 765 660 570 432 278 195 145


58/85


APPENDIX-1



SHEET OF 7953

FORM NO. 120 R1

ISSUE

R3

KPL RANGE


o C )




TYPE AH 1 10 60 5 10 30 60 90 2 3 5 8 10

KPL5P 5 6.9 5.8 4.6 3.7 3.3 2.8 2.3 2 1.7 1.3 0.9 0.6 0.5

KPL11P 11 15.2 12.8 10.2 8.2 7.2 6.2 5.1 4.3 3.7 2.9 2 1.3 1KPL19P 19 26.3 22.1 17.6 14.2 12.5 10.7 8.8 7.4 6.3 5.2 3.4 2.2 1.8

KPL29P 29 40.2 33.7 25.9 21.7 19.1 16.3 13.4 11.3 9.7 7.6 5.2 3.4 2.7

KPL39P 39 53.1 44.4 36.7 29.8 25.9 21.7 18 15.2 13 10.2 7 4.5 3.6

KPL49P 49 67.2 56.5 46.4 38.6 33.7 27.8 22.7 19.2 16.3 12.8 8.7 5.7 4.6

KPL60P 60 80.7 67.5 54.7 46.5 40.6 33.6 27.5 23.5 20 15.7 10.7 7 5.6

KPL70P 70 92.6 78.2 63.8 50.6 44.1 35.4 29.3 25.1 23 18.3 12.5 8 6.5

KPL75P 75 107 85.7 66.7 52.7 45.9 36.3 30.2 27 23.2 19.4 13.4 8.8 7.1

KPL90P 90 123 98.1 77 58.8 51.2 38.9 32.9 29.4 27.1 22.7 16.1 10.3 8.3

KPL100P 100 139 111 87.5 66.9 58.2 44.2 37.7 33.7 31.1 25 17.8 11.8 9.5

KPL130P 130 170 136 108 82.8 72.3 55.1 47.4 42.2 39 32.5 23.2 14.8 12

KPL155P 155 200 163 129 100 88.1 66.7 58.1 51.8 47.9 40 27.7 18.2 14.7

KPL190 190 231 189 150 118 103 80.7 69.9 62.4 57.6 48.2 33.9 21.9 17.7KPL220P 220 260 214 171 135 118 93 81.8 72.9 67.4 56.4 39.3 25.6 20.7

KPL250P 250 288 238 191 151 133 105 93.2 83.2 76.9 64.3 44.6 29.2 23.6

KPL280P 280 312 263 211 168 148 118 105 93.7 86.6 72.4 50 32.9 26.6

KPL320P 320 338 290 233 184 163 130 117 104 95.4 80.5 57.1 36.7 29.5

KPL350P 350 365 311 254 201 178 143 128 115 106 88.5 62.5 40.3 32.4

KPL380P 380 400 343 275 218 193 156 140 125 116 95.5 67.8 44 35.4

KPL410P 410 437 370 297 236 207 169 152 136 125 105 73.2 47.7 38.4

KPL440P 440 460 395 330 273 245 201 172 150 138 118 78.5 54.7 44.2

KPL480P 480 490 428 357 296 265 218 186 162 149 129 85.7 59.4 48

KPL500P 500 594 488 406 316 286 236 198 176 160 135 89.2 62.5 50.5

KPL580P 580 662 544 456 362 328 266 224 200 182 155 103 71.7 57.9

KPL655P 655 730 600 506 408 370 296 250 224 204 175 117 81 65.4

KPL730P 730 795 661 556 452 409 332 282 249 228 196 130 90.3 72.9

KPL810P 810 860 722 606 496 448 368 314 274 252 217 145 100 80.9

KPL885P 885 920 790 660 544 490 402 344 300 276 237 158 109 88.4

KPL960P 960

battery sizing design basis tce

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