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Training Programme For Assistant Engineers (2009-10) : Topic: DC Batteries and Battery Chargers

This document provides details for sizing and selecting batteries and chargers for an industrial plant. It includes: 1. Sizing a lead-acid battery for the plant based on load details like a 5kW emergency motor, 25 solenoid valves, indicator lamps, and more. 2. Calculations to size the battery with NiCad batteries. 3. Templates for battery and charger datasheets. 4. Tables listing batteries, chargers, and DC boards for a sample power plant. 5. Questions addressing battery and charger sizing factors, specifications, tests, and a site visit assignment.

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ashok
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158 views

Training Programme For Assistant Engineers (2009-10) : Topic: DC Batteries and Battery Chargers

This document provides details for sizing and selecting batteries and chargers for an industrial plant. It includes: 1. Sizing a lead-acid battery for the plant based on load details like a 5kW emergency motor, 25 solenoid valves, indicator lamps, and more. 2. Calculations to size the battery with NiCad batteries. 3. Templates for battery and charger datasheets. 4. Tables listing batteries, chargers, and DC boards for a sample power plant. 5. Questions addressing battery and charger sizing factors, specifications, tests, and a site visit assignment.

Uploaded by

ashok
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Training Programme for Assistant Engineers (2009-10)

Assignment (Electrical)

Topic : DC Batteries and Battery Chargers


1

Size a battery (lead acid) required for the industrial plant in assignment #1. One battery
set is sufficient for the plant.
a) Inputs are :
Switchgear details are as per SLD of the assignment 1
It is an industrial plant.
One DC emergency motor is required to be run for 1 hour after AC power supply

b)
c)
d)
e)
f)

is lost. Its rating is 5 kW.


It is a small plant (Clue: Voltage is 110V DC)
No. solenoid valves : 25
Inverters for I+C system is derived from the same battery and its load is expected

to be about 3 kW
Apart from the switchgear indicating lamps, control panels in the plant have about

40 indicating lamps.
Auxiliary relays can be assumed as 1 per HV circuit and each LV ACB feeder.
Control room lighting on DC is about 1 kW
Safety movement lighting required for the plant is about 2.5 kW
There are about 3 control panels totally having 60 annunciation windows.
Maximum time duration of possibility of AC power failure is 10 Hours
Maximum temp of site is 43 deg C and minimum is about 7 deg C
This plant is proposed to have 1x100% battery. Standby charger is needed.
Create a load table as per Appendix 3 of design guide
Battery sizing table as per table in appendix 3 of design guide
Create battery and charger SLD for the above.
Indicate the ratings for the selected chargers
Indicate the no. of cells and how you arrived at it and the calculation for cell tap ypu

will select.
g) References for the values of KT factor shall be clear in the answer
2

Make battery AHr sizing calculations for above with Ni cad batteries and answer f)
above.
Topic : DC Batteries and Battery Chargers (Contd)
3

Prepare a data sheet A1 for the lead acid storage battery for the above

Prepare datasheet A1 for the battery charger for the above

Answer the following:

Training Programme for Assistant Engineers (2009-10)


Assignment (Electrical)

a)

Indicate a table of batteries, chargers and DC boards indicating the purpose for a
2x210 MW coal based power plant with 400 kV switchyard. AHr ratings can be
left as Blank. This shall include the I+C Batteries of the plant also and exclude
UPS
Sl.N
o

Designation

rating

Type

Purpose

b)

What is the starting current for DC motors to be considered for battery sizing in
terms of full load current when it is not specified/available.

Ans

The starting current of DC Motors is take as 3.5 times the full load current when
the starting current value is not specified or available. If step resistor is provided
then starting current value of DC Motors is taken as 2.5 times of full load current.

c)

Indicate the differences in the sizing calculation for the battery in case of lead acid
and Ni-Cad. (name of the factors, Factor values)

d)

List the float charger sizing criteria as per design guide.

Ans

The float charger sizing criteria is based on


a) DC load i.e. continous load
b) The float charging current of the battery
c) Largest DC Motor running current
d) 25% margin over above loads

e)

Indicate the range of adjustment specified for automatic voltage regulator of float
charger and automatic constant current regulator of boost charger

Ans

The range of adjustment specified for automatic voltage regulator of float charger
is 1 % of set DC bus voltage with AC input voltage variation of 10%,
frequency variation of 5%, and DC load variation from 0 100%. In case of
automatic constant current regulator of boost charger, the DC output current shall
be stablilised within 2% for AC input voltage and frequency variation of
10% and 5% respectively.

f)

What is the allowable ripple from float charger as per TCE specification.

Ans

As per TCE specification, the ripple content shall be within 1% of DC output


nominal voltage with battery disconnected.

g)

For which selector switches make before break contact is specified and why it
is needed in that circuit

Training Programme for Assistant Engineers (2009-10)


Assignment (Electrical)

h)

What is the degree of protection called for the charger in TCE specification.

Ans

The degree of protection for the charger is IP 42 in TCE specifications.

i)

Indicate the difference between the High discharge performance and the normal
discharge performance of the tubular battery.

j)

See IS and indicate the explanation of ampere hour and kWHr efficiencies of the
battery. Indicate their typical values for tubular, Plante lead acid batteries and
NiCad batteries

k)

Why lead coating is specified for all the metallic current carrying parts. What is
the minimum thickness asked in TCE specification.

Ans

In order to withstand the corrosion caused due to the sulphuric acid, lead coating
is specified for all metallic current carrying parts. The minimum lead coating
thickness should not be less than 0.025mm as per TCE specification.

l)

List the type , routine and acceptance tests for Plante type Battery. Also list out
difference in these tests between the Plante and tubular type.

Topic : DC Batteries and Battery Chargers (Contd)


m)

Visit the battery room in our St. Marks road office (with office electrician) and
list out:
i)

What type of battery is it?

ii)

What AH capacities are provided?

iii)

What is the voltage of each Battery?

iv)

Write about the provision of cell insulator, stand insulator, layout


compliance wrt sketch of typical layout in design guide.

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