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01 Revised as per GNFC/PDIL comments 16/09/2010

00 First Issue SAPO / VJS 03/07/2010

Approved
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THIS DOCUMENT AND ANY DATA AND INFORMAnON CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF L&T ENGINEERING AND THE COPYRIGHT THEREIN IS VESTED IN DEC. NO PART
OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY PURPOSE WHATSOEVER EXCEPT WITH THE PRIOR WRITTEN
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 LARSEN & TOUBRO LIMITED
E&C DIVISION DOCUMENT NO:-
ASGP-LTEM-EL-CL-0055
DC SYSTEM SIZING
AMMONIA SYNGAS CALCULATION REVISION : 01
PROJECT : GENERATION PLANT

CUSTOMER : GNFC, BHARUCH PAGE : 2 OF 6

CONTENTS

SECTION DESCRIPTION PAGE NO.

1.0 SCOPE OF WORK 3

2.0 REFERENCE DOCUMENTS 3

3.0 SITE CONDITION 3

4.0 DC SUPPLY SYSTEM 3

5.0 LOAD CYCLE 4

6.0 BATTERY SIZING 5

7.0 BATTERY CHARGER SIZING 6

8.0 CONCLUSION 6

9.0 ANNEXURE 6
 LARSEN & TOUBRO LIMITED
E&C DIVISION DOCUMENT NO:-
ASGP-LTEM-EL-CL-0055
DC SYSTEM SIZING
AMMONIA SYNGAS CALCULATION REVISION : 01
PROJECT : GENERATION PLANT

CUSTOMER : GNFC, BHARUCH PAGE : 3 OF 6

1.0 SCOPE OF WORK

This document details the DC System Sizing Calculations for Ammonia Syngas Generation Plant,
GUJARAT NARMADA VALLEY FERTILIZERS CO. LTD, Bharuch, Gujarat, India.

2.0 REFERENCE DOCUMENTS

GNFC Contract - Annexure 6.2., : Electrical Design Philosophy
Appendix A
GNFC Contract - Annexure 6.2 : Engineering Design Basis-Electrical
ASGP - LTEM - EL - SP - 0528 : Specification for DC supply system.
IEEE std 485 - 1997 : IEEE recommended practice for sizing Lead Acid Batteries
for stationary applications.
3.0 SITE CONDITIONS
Maximum temp. : 50 deg. C
Atmosphere : Dusty, High humidity, Salt laden winds, air
borne chemical contaminants & Corrosive as found in
industrial process plants.
Altitude : 19.2m above sea level
4.0 DC SUPPLY SYSTEM
4.1 DC System comprises of battery charger (ASGP – CH – 60401), battery bank (ASGP – BA –
60401) and DC distribution board (ASGP – DCDB – 60431).
The details of DC system components are as follows:
i Input AC supply : 415 ± 10 % V AC, 50 ± 3 Hz.
ii Output DC Supply : 220 V
iii Battery Type : Lead Acid with Plante positive plate (13 a of Appendix A)
iv Backup time : 3 hours (13 a of Appendix A)
v Minimum design temperature : 5 deg C
vi Design Margin : 40 % (13 a of Appendix A)

4.2 DC system shall provide control supply for switchgear (Switch boards, relay panel, etc) and DC
critical lighting.
i 11 kV Main Switchboard (ASGP – SG – 60101)
ii 11 kV Plant Switchboard (ASGP – SG – 60102)
iii 3.3 kV Switchboard (ASGP – SG – 60103)
iv 3.3 kV VFD system breakers
v 415 V PMCC – 1 (ASGP – PMCC– 60301)
vi 415 V PMCC – 2 (ASGP – PMCC – 60302)
vii 415 V EPMCC (ASGP – EPMCC – 60303)
viii 415 V HVAC PMCC (ASGP – HVACPMCC – 60304)
 LARSEN & TOUBRO LIMITED
E&C DIVISION DOCUMENT NO:-
ASGP-LTEM-EL-CL-0055
DC SYSTEM SIZING
AMMONIA SYNGAS CALCULATION REVISION : 01
PROJECT : GENERATION PLANT

CUSTOMER : GNFC, BHARUCH PAGE : 4 OF 6

ix 415 V MCC – 1 (ASGP – MCC – 60311)

x 415 V MCC – 2 (ASGP – MCC – 60312)
xi 415 V PDB (ASGP – PDB – 60331)
xii 11KV (main) relay panel (ASGP – SG – RCP – 60101)
xiii 11KV (plant) relay panel (ASGP – SG –RCP – 60102)
xiv 3.3KV relay panel (ASGP–SG – RCP – 60103)
xv PMCC1 Relay Panel (ASGP – PMCC – RCP – 60301)
xvi PMCC2 Relay Panel (ASGP – PMCC – RCP – 60302)
xvii MCC1 Relay Panel (ASGP – MCC – RCP – 60311)
xviii MCC2 Relay Panel (ASGP‐MCC RCP 60312)
xix Emergency PMCC relay panel (ASGP‐MCC RCP 60312)
xx DC critical lighting (Substation, Control Room, DG Room and selected process area)

5.0 DC LOAD CYCLE

5.1 Assumptions:
a. Battery capacity is determined based on the most severe duty cycle imposed on the battery.
The most severe condition occurs under total power failure with no DG backup.
b. Loads of indication lamps, numerical relays, auxillary relays, annunciator, Multi function
meters (MFM), etc are considered based on HV/LV switchboard and relay panel vendor inputs
/ past project database.
c. DC critical lights considered at escape routes of substation, control room, DG set room and
selected process area.
d. As per 4.1 (vi), 40 % battery design margin considered for future Breaker and relay panel
additions.
5.2 Continuous Load:
a. Numerical relays
1 b. Multifunction meters (MFM): For incomers and HT motor feeders only.
c. Indication lamps:
• Following indications are considered on HT switch boards & relay panel:
i Breaker ‘ON’ or ‘OFF’ (HT switch board)
ii Breaker ‘ON’ or ‘OFF’ (Relay Panel)
iii Breaker ‘AUTO TRIP’ (HT switch board)
iv Breaker ‘AUTO TRIP’ (Relay Panel)
v Breaker spring Charged. (HT switch board)
vi Breaker spring Charged. (Relay Panel)
vii Upstream breaker ‘ON’ or ‘OFF’ (Only for 11 kV Main Incomers).
• Following indications are considered on LT switch boards:
i Breaker ‘ON’ or ‘OFF’.
ii Breaker ‘AUTO TRIP’.
iii Breaker Trip circuit Healthy.
iv Breaker spring Charged.
v Synchronization check (Only for Bus couplers)
vi Remote Interlock status (Only for Incomers).
 LARSEN & TOUBRO LIMITED
E&C DIVISION DOCUMENT NO:-
ASGP-LTEM-EL-CL-0055
DC SYSTEM SIZING
AMMONIA SYNGAS CALCULATION REVISION : 01
PROJECT : GENERATION PLANT

CUSTOMER : GNFC, BHARUCH PAGE : 5 OF 6

• Following indications are considered on Relay panel for LT incomers:

i Breaker ‘ON’ or ‘OFF’.
ii Breaker ‘AUTO TRIP’.
iii Breaker spring Charged.
d. Annunciator on relay panel: 720 (approx) - the no of windows is considered for 60 nos of
1 feeders (60 nos of 12 window annunciator). Out of 720 windows less than 50% i.e 360
windows would glow for blackout condition.
e. Lockout supervision relay for all breaker feeders
1
f. DC supervision relay for each switchboard
g. DC Critical lights
• 60 W GLS DC critical lights are considered as follows:
i Substation : 05 Nos
ii Control Room : 03 Nos
iii DG Room : 03 Nos
iv Process area : 19 Nos
5.3 First Minute Load:
Battery has to supply following momentary loads during first minute:
i Tripping of all Incomer breakers.
ii Tripping of all Motor feeder breakers.
iii Tripping of 11 kV capacitor feeders.
5.4 Last Minute Load:
When main power supply resumes, all incomer breaker feeders up to DC charger is to be closed to
resume supply to DC charger and then other feeders can be closed.
Battery has to supply following momentary loads during last minute:
i Closing of 11 kV main incomers.
ii Closing of 11 kV Plant incomers.
iii Closing of 415 V PMCC - 1 incomers.
iv Closing of EPMCC incomers

6.0 BATTERY SIZING

Battery ampere-hours is worked out on basis of load cycle and IEEE std 485 - 1997. Following
factors are taken into account:
i. Nominal system voltage : 220 V
ii. Nominal cell voltage : 2 V (13 a of Appendix A)
iii. End cell voltage : 1.85 V (13 a of Appendix A)
iv. Temperature correction factor : 1.198 (for 5 deg C) (As per IEEE 485)
v. Ageing factor : 1.0 (for Lead acid Plante battery) (As per IEEE 485)
vi. Design Margin : 40 % (13 a of Appendix A)
 LARSEN & TOUBRO LIMITED
E&C DIVISION DOCUMENT NO:-
ASGP-LTEM-EL-CL-0055
DC SYSTEM SIZING
AMMONIA SYNGAS CALCULATION REVISION : 01
PROJECT : GENERATION PLANT

CUSTOMER : GNFC, BHARUCH PAGE : 6 OF 6

7.0 BATTERY CHARGER SIZING

Double redundant float cum boost battery charger (2 X 100 %) is sized for one of the following
duty conditions, whichever is higher.
i. Offline boost charging of the battery assembly:
Charger rating = Float charger rating or 15% of battery AH capacity

ii. Online float charging of the battery assembly while feeding the complete DC load
Charger rating =Continuous load requirement + Float charging current of battery (1.5
mA/Ah of Battery)

8.0 CONCLUSION
i. Expected Battery size : 300 AH
ii. Expected charger rating : 50 A

9.0 ANNEXURE

Annexure I – Sizing Calculation sheet (7 Pages).

 LARSEN & TOUBRO LIMITED DOCUMENT NO:
E&C DIVISION DC SYSTEM SIZING ASGP-LTEM-EL-CL-0055
ASGP LTEM EL CL 0055
PROJECT : AMMONIA SYNGAS CALCULATION REVISION : 01
GENERATION PLANT
CUSTOMER : GNFC
GNFC, BHARUCH ANNEXURE - I

CONTINUOUS LOAD
A SWITCHGEAR LOAD
1 Numerical relays - Relay Panel
2 Multifunction meters - Relay Panel
3 Indication
d cat o Lamps
a ps - Both
ot Breaker
ea e and
a d Relay
e ay Panel
a e
4 A illi y Relays
Auxilliary R l y / Contactors
C t t - Both
B th Breaker
B k and dR
Relay
l yPPanell

Lockout supervision relay

No of Numerical Relays
y MFM Indication Lamps
p Auxilliaryy Relays
y / Contactors
Switchgear Feeder Type & DC supervision relay
feeders/Panel
Watts/feeder Total Watts/feeder Total Lamps/Feeder Watts/Lamp Total Watts/feeder Total Watts/feeder Total
Incomer 2 30 5
30.5 61 10 20 7 1 14 3 13
3.13 6 26
6.26 20 40
B C
Bus-Couplerl 1 12 5
12.5 12 5
12.5 0 0 6 1 6 6 26
6.26 6 26
6.26 34 34
BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
11 kV M
Main
i SWBD
Transformer Feeder
(ASGP – SG – 60101) 3 14 42 0 0 6 1 18 10 30
(Sp )
((Spare) 3.13
3 13 9.39
9 39
&
Motor Feeder 0 7 0 10 0 6 1 0 3.13 0 15 0
(ASGP SG RCP 60101)
(ASGP-SG-RCP-
IG Feeder 1 12 5
12.5 12 5
12.5 0 0 6 1 6 3 13
3.13 3 13
3.13 15 15
C p it Feeders
Capacitor F d 2 12 5
12.5 25 0 0 6 1 12 3 13
3.13 6 26
6.26 15 30
Outgoing Feeders 2 12.5 25 0 0 6 1 12 3.13 6.26 15 30

Incomer 2 30.5 61 10 20 7 1 14 3.13 6.26 20 40

11 kV Plant SWBD
Bus-Coupler 1 12 5
12.5 12.5
12 5 0 0 6 1 6 6 26
6.26 6 26
6.26 34 34
(ASGP – SG – 60102)
BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
&
Transformer Feeder 8 14 112 0 0 6 1 48 3.13 25.04 10 80
(ASGP SG RCP 60102)
(ASGP-SG-RCP-
Motor Feeder 12 7 84 10 120 6 1 72 3 13
3.13 37 56
37.56 15 180

Incomer 2 30.5 61 10 20 7 1 14 3.13 6.26 20 40

3 3 kV SWBD
3.3
Bus Coupler
Bus-Coupler 1 12 5
12.5 12.5
12 5 0 0 6 1 6 6 26
6.26 6 26
6.26 34 34
(ASGP – SG – 60103)
BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
&
Motor Feeder 8 7 56 10 80 6 1 48 3.13 25.04 15 120
(ASGP SG RCP 60103))
((ASGP-SG-RCP-
VFD Feeders 4 12 5
12.5 50 0 0 6 1 24 3 13
3.13 12 52
12.52 10 40

Input breaker 3 7 21 10 30 7 1 21 3.13

3 13 9.39
9 39 34 102
3 3 kV VFD System Breakers Output breaker
3.3 4 0 0 0 0 10 1 40 0 0 20 80
Bypass breaker 2 7 14 10 20 10 1 20 3.13 6.26 34 68

IIncomer 2 22.5
22 5 45 10 20 8 1 16 3.13
3 13 6.26
6 26 30 60
415 V PMCC1 Bus-Coupler
Bus Coupler 1 12.5 12.5 0 0 8 1 8 3.13 3.13 31 31
(ASGP – PMCC
PMCC– 60301) BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
& M t Feeder
Motor F d 7 12 5
12.5 87 5
87.5 0 0 4 1 28 3 13
3.13 21 91
21.91 12 84
(ASGP-PMCC-RCP-
(ASGP PMCC RCP 60301) Outgoing Feeders (ACB) 8 12.5 100 0 0 4 1 32 3.13 25.04 12 96
MCCB Feeders 2 0 0 0 0 4 1 8 0 0 0 0

IIncomer 2 22.5
22 5 45 10 20 8 1 16 3.13
3 13 6.26
6 26 30 60
415 V PMCC2
(ASGP – PMCC – 60302) Bus-Coupler
Bus Coupler 1 12.5 12.5 0 0 8 1 8 3.13 3.13 31 31
& BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
(ASGP-PMCC-RCP- 60302) M t Feeder
Motor F d 7 12 5
12.5 87 5
87.5 0 0 4 1 28 3 13
3.13 21 91
21.91 12 84
Outgoing Feeders (ACB) 8 12.5 100 0 0 4 1 32 3.13 25.04 12 96

Incomer
co e 3 22.5
5 6 5
67.5 10
0 30 8 1 24 3 3
3.13 9 39
9.39 30 90
Bus-Coupler 1 12 5
12.5 12 5
12.5 0 0 8 1 8 3 13
3.13 3 13
3.13 31 31
415 V EPMCC
BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
(ASGP – EPMCC – 60303) &
Motor Feeder 4 12.5 50 0 0 4 1 16 3.13 12.52 12 48
(ASGP EPMCC RCP 60303)
(ASGP-EPMCC-RCP-
Outgoing Feeders (ACB) 1 12 5
12.5 12 5
12.5 0 0 4 1 4 3 13
3.13 3 13
3.13 12 12

Page 1 of 7
 LARSEN & TOUBRO LIMITED DOCUMENT NO:
E&C DIVISION DC SYSTEM SIZING ASGP-LTEM-EL-CL-0055
ASGP LTEM EL CL 0055
PROJECT : AMMONIA SYNGAS CALCULATION REVISION : 01
GENERATION PLANT
CUSTOMER : GNFC
GNFC, BHARUCH ANNEXURE - I

Non ACB Feeders 69 0 0 0 0 0 1 0 0 0 0 0

415 V HVAC PMCC Incomer 2 22.5 45 10 20 8 1 16 3.13 6.26 30 60

(ASGP – HVACPMCC – Bus-Coupler 1 12 5
12.5 12.5
12 5 0 0 8 1 8 3 13
3.13 3 13
3.13 31 31
60304) & BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
(
(ASGP-HVACPMCC-RCP- Motor Feeder 5 12.5 62.5 0 0 4 1 20 3.13 15.65 12 60
60304) Non ACB Feeders 30 0 0 0 0 0 1 0 0 0 0 0

415 V MCC1 Incomer 2 22.5 45 10 20 8 1 16 3.13 6.26 30 60

(ASGP – MCC – 60311) BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
& B C pl
Bus-Coupler 1 12 5
12.5 12 5
12.5 0 0 8 1 8 3 13
3.13 3 13
3.13 31 31
(ASGP - MCC -RCP-
RCP 60311) Non ACB Feeders 90 0 0 0 0 0 0 0 0 0 0 0

415 V MCC2 Incomer

co e 2 22.5
5 45
5 10
0 20
0 8 1 16
6 3.13
3 3 6 6
6.26 30 60
(ASGP – MCC – 60312) BUS PT 2 14 28 0 0 0 1 0 6 12 0 0
& B s Co pler
Bus-Coupler 1 12 5
12.5 12 5
12.5 0 0 8 1 8 3 13
3.13 3 13
3.13 31 31
((ASGP-MCC RCP-60312)) Non ACB Feeders 111 0 0 0 0 0 1 0 0 0 0 0

415 V PDB Incomer 3 22.5 67.5 10 30 8 1 24 3.13 9.39 30 90

(ASGP – PDB – 60331)
Bus-Coupler
Bus Coupler 1 12.5 12.5 0 0 8 1 8 3.13 3.13 31 31
&
(ASGP PDB -RCP-60331)
(ASGP-PDB RCP 60331) N ACB Feeders
Non F d 8 0 0 0 0 3 1 24 0 0 0 0

S bt t l
Subtotal 1861 5
1861.5 470 757 483 6
483.6 2174
TOTAL 5746.1

B RELAY PANEL ANNUNCIATION LOAD

Total
T t l 720 N
Nos ((60 nos off 12 window)
i d ) off annunciation
i ti windows
i d off 1
1.5
5 W each
h off which
hi h only
ly 50 % ((max)) will
ill g
glow
l d
during
i gppower bl
blackout.
k t
DC Load of Relay panel annunciation (360 X 1.5) 540

C DC
CCCRITICAL
C LIGHTING
G G LOAD
O LOAD
O

Total 30 Nos of GLS DC Critical lights of 60 W each

DC Critical lighting load (30 X 60) 1800

D Total
T t l DC load
l d 8086.1
8086 1 W
Total DC load in Amp 36 76
36.76 A

Page 2 of 7
 LARSEN
S & TOUBRO
OU O LIMITED DOCUMENT
OCU NO:
O
E&C DIVISION DC SYSTEM SIZING ASGP-LTEM-EL-CL-0055
ASGP LTEM EL CL 0055

PROJECT : AMMONIA SYNGAS

CALCULATION
REVISION : 01
GENERATION PLANT

CUSTOMER : GNFC
GNFC, BHARUCH ANNEXURE - I

FIRST MINUTE LOAD

S it h
Switchgear F d Description
Feeder D i ti N off F
No Feeders
d O
Operation
ti W tt /F d
Watts/Feeder T t l Watts
Total W tt
Incomer 1 1 Tripping 350 350
Incomer 2 1 Tripping
pp g 350 350
11 kV Main SWBD
Generator Feeders 1 Tripping 350 350
Capacitor Feeders 2 Tripping 350 700
I
Incomer 1 1 Ti i g
Tripping 350 350
11 kV Plant SWBD Incomer 2 1 Tripping 350 350
Motor Feeders 12 Tripping 350 4200
Incomer 1 1 Tripping 350 350
3.3 kV SWBD Incomer 2 1 Tripping
pp g 350 350
Motor Feeders 8 Tripping 350 2800
Incomer 1 1 Tripping 180 180
415 V PMCC1 I
Incomer 2 1 T ippi g
Tripping 180 180
Motor Feeders 7 Tripping 180 1260
Incomer 1 1 Tripping 180 180
415 V PMCC2 I
Incomer 2 1 Ti i
Tripping 180 180
Motor Feeders 7 Tripping 180 1260
Incomer 1 1 Tripping 180 180
415 V EPMCC Incomer 2 1 Tripping 180 180
Motor Feeders 2 Tripping
pp g 180 360
Incomer 1 1 Tripping 180 180
415 V HVAC PMCC Incomer 2 1 Tripping 180 180
M t Feeders
Motor F d 5 T ippi g
Tripping 180 900
Incomer 1 1 Tripping 180 180
415 V PDB Incomer 2 1 Tripping 180 180
M t Feeders
Motor F d 0 Ti i
Tripping 180 0
Incomer 1 1 Tripping 180 180
415 V MCC1 Incomer 2 1 Tripping 180 180
Motor Feeders 0 Tripping 180 0
Incomer 1 1 Tripping
pp g 180 180
415 V MCC2 Incomer 2 1 Tripping 180 180
Motor Feeders 0 Tripping 180 0

Total 16450 W

Total
o a Cu
Current
e 74.78
8 A

Note: Breaker Spring

p g Charging
g g Motor (W)
( ) Closing
g coil (W)
( ) Tripping
pp g Coil (W)
( )
VCB 770 200 200
ACB 154 300 30

Burden for Lockout relay (VAJHM 13) = 150 W for 220 V DC

Page 3 of 7
 LARSEN & TOUBRO
DOCUMENT NO:
LIMITED
E&C DIVISION
DC SYSTEM SIZING ASGP-LTEM-EL-CL-0055
ASGP LTEM EL CL 0055

PROJECT : AMMONIA SYNGAS

CALCULATION
REVISION : 01
GENERATION PLANT

CUSTOMER : GNFC
GNFC, BHARUCH ANNEXURE - I

LAST MINUTE LOAD

Feeder Total
S it hg
Switchgear N off F
No Feeders
d O
Operation
ti W tt /F d
Watts/Feeder
Description Watts
Incomer 1 1 Closing & Spring charging 970 970
11 kV Main SWBD
I
Incomer 2 1 Cl i g & Spring
Closing Sp i g charging
h gi g 9 0
970 9 0
970
Incomer 1 1 Closing & Spring charging 970 970
11 kV Pl
Plantt SWBD
Incomer 2 1 Closing & Spring charging 970 970
Incomer 1 1 Closing & Spring charging 454 454
415 V PMCC1
I
Incomer 2 1 Cl i g & Spring
Closing Sp i g charging
h gi g 4 4
454 4 4
454
Incomer 1 1 Closing & Spring charging 454 454
415 V EPMCC
Incomer 2 1 Closing & Spring charging 454 454

Total 5696 W

Total Current 25 9
25.9 A

Note: Breaker Spring Charging Motor (W) Closing coil (W) Tripping Coil (W)
VCB 770 200 200
ACB 154 300 30

Page 4 of 7
 LARSEN & TOUBRO LIMITED DOCUMENT NO:
E&C DIVISION DC SYSTEM SIZING ASGP LTEM EL CL 0055
ASGP-LTEM-EL-CL-0055
CALCULATION
PROJECT : AMMONIA SYNGAS
REVISION : 01
GENERATION PLANT

CUSTOMER : GNFC
GNFC, BHARUCH ANNEXURE - I

DC LOAD CYCLE
LOAD PROFILE (WATT)
DC
NO. SYSTEM DESCRIPTION Q'TY UNIT STANDING LOAD First Min Load Last Min Load REMARKS
NO.
((0~180 MIN)) (0~1
( MIN.)) (179~180
( MIN.))
TOTAL LOAD SUMMARY FOR 220 V DC SYSTEM FOR SUBSTATIONS
1 - 220V DC SUPPLY 1 SET 8,086 16,450 5,696 WATT
36.76 74.77 25.89 AMPERE

LOAD CYCLE CALCULATION:

SYSTEM VOLTAGE ((VDC)) = 220
a) CO
CONTINIOUS
OUS LOAD
O ((AMPS)
S) = 36.76
36 6
b) FIRST MINUTE LOAD (AMPS) = 74.77 36.76 111.53
c) LAST MINUTE LOAD (AMPS) = 25.89 36.76 62.65

BATTERY BACK-UP TIME (MIN) = 180

BATTERY DUTY CYCLE TABLE:

TIME (MINUTES) CURRENT (AMPS)
0 111 53
111.53
1 111 53
111.53
1 36 76
36.76
179 36 76
36.76
179 62 65
62.65
180 62.65

BATTERY DUTY CYCLE

120.00

100.00
MP
-AMP
URRENT-AMP
RENT-AMP
NT-AMP
CURRENT-AMP

80.00

60.00 Time

40.00

20 00
20.00

0 00
0.00
0 20 40 60 80 100 120 140 160 180 200

TIME-MIN

Page 5 of 7
 LARSEN & TOUBRO LIMITED DOCUMENT NO:
E&C DIVISION DC SYSTEM SIZING ASGP LTEM EL CL 0055
ASGP-LTEM-EL-CL-0055
PROJECT : AMMONIA SYNGAS CALCULATION
REVISION : 01
GENERATION PLANT
C S O
CUSTOMER :G
GNFC,
C BHARUCH
C ANNEXURE - I

LEAD ACID PLANTE BATTERY SIZING CALCULATIONS AS PER IEEE - 485

NOMINAL SYSTEM VOLTAGE (VDC) : 220 (AS SPECIFIED)

MINIMUM S
SYSTEM
S VOLTAGE
O G ((VDC)
C) : 198 ((AS
SSSPECIFIED)
C )
MAXIMUM SYSTEM VOLTAGE (VDC) : 242 (AS SPECIFIED)
NOMINAL CELL VOLTAGE (VDC) : 2 (AS PER IEEE-485)
END CELL VOLTAGE (VDC) : 1.85 (AS PER IEEE-485)
FLOAT OR BOOST VOLTAGE ((VDC)) : 2.3 ((AS PER IEEE-485))

NUMBER OF CELLS : NOMINAL SYSTEM VOLTAGE / NOMINAL CELL VOLTAGE 110 NOS.
MINIMUM SYSTEM VOLTAGE / END CELL VOLTAGE 108 NOS.
MAXIMUM SYSTEM VOLTAGE / FLOAT OR BOOST VOLTAGE 106 NOS.

NUMBER OF CELLS = 110 NOS

NOS.

AGING FACTOR : 1 (FOR LEAD ACID PLANTE CELLS - IEEE 485)

SPARE CAPACITY (PERCENTAGE) : 40 (SPECIFIED)
MINIMUM OPERATING AMB
AMB. TEMP : 5°C
TEMPERATURE CORRECTION FACTOR : 1 198
1.198 (AS PER IEEE
IEEE-485
485 TABLE)

BATTERY DUTY CYCLE

BATTERY BACK-UP TIME : 180 MIN.
A1 : 111.53 AMPS FOR 1 MIN. FOLLOWED BY
A2 : 36.76 AMPS FOR NEXT 178 MIN. FOLLOWED BY
A3 : 62.65 AMPS FOR LAST 1 MIN.

K-FACTOR
K FACTOR AS PER IEEE
IEEE-485
485

CORRECTED K K- FACTOR
DURATION (MINUTE)
((AS
S PER IEEE-485)
85)
1 1.200
178 3.800
179 3.800
180 3.800

CALCULATION OF BATTERY AMPERE-HOUR :

(1) (2) (3) (4) (5) (6) (7)

REQUIRED SECTION
DURATION OF CAPACITY RATING SIZE (3) x (6)
SIZE- RATE
CHANGE IN LOADS TIME TO END SECTION
PERIOD LOADS (AMPS) PERIOD FACTOR AT t MIN.
(AMPS) (MINUTES) POS
POS.
((MINUTES)) RATE ((Kt)) NEG.
G VALUE
U
VALUE
SECTION 1 FOR FIRST PERIOD ONLY AND IF A1>A2 THEN GO TO SECTION
SECTION-1 SECTION-2
2
1 A1 111 53
111.53 A1 0
A1-0 111 53
111.53 M1 1 T M1
T=M1 1 1 200
1.200 133 83
133.83 0.00
0 00
SECTION 1 SUB TOTAL AH
SECTION-1 133
133.83
83 0 00
0.00
SECTION-1 TOTAL AH 133.83
SECTION-2 FOR FIRST TWO PERIODS ONLY AND IF A3>A2 THEN GO TO SECTION-3
1 A1 111.53 A1-0 111.53 M1 1 T=M1+M2 179 3.800 423.81 0.00
2 A2 36.76 A2-A1 -74.77 M2 178 T=M2 178 3.800 0.00 284.14
SECTION-2
SECTION 2 SUB TOTAL AH 423.81 284.14
SECTION-2
SECTION 2 TOTAL AH 139.67
SECTION-3 FOR FIRST THREE PERIODS ONLY AND IF A4>A3 THEN GO TO SECTION-4
1 A1 111 53
111.53 A1-0 111 53
111.53 M1 1 T=M1+M2+M3 180 3 800
3.800 423 81
423.81 0 00
0.00
2 A2 36 76
36.76 A2-A1 -74 77
-74.77 M2 178 T=M2+M3 179 3 800
3.800 0 00
0.00 284.14
284 14
3 A3 62 65
62.65 A3-A2 25 89
25.89 M3 1 T=M3 1 1 200
1.200 31 07
31.07 0 00
0.00
SECTION 3SUB TOTAL AH
SECTION-3SUB 454 87
454.87 284 14
284.14
SECTION 3 TOTAL AH
SECTION-3 170 74
170.74

MIN. CAPACITY REQD. = 170.74 AH

BY APPLYING TEMP. CORRECTION FACTOR = 204.54
BY APPLYING AGING FACTOR = 204.54 AH
BY APPLYING SPARE CAPACITY = 286.36 AH

CELL SELECTED 300.00 AH

Page 6 of 7
 LARSEN & TOUBRO LIMITED DOCUMENT NO:
E&C DIVISION DC SYSTEM SIZING ASGP LTEM EL CL 0055
ASGP-LTEM-EL-CL-0055
CALCULATION
PROJECT : AMMONIA SYNGAS
REVISION : 01
GENERATION PLANT

CUSTOMER : GNFC
GNFC, BHARUCH ANNEXURE - I

BATTERY CHARGER SIZING

INCOMING :

Voltage
V lt g : 415 ± 10% VAC
Freqyency : 50± 3% Hz

OUTGOING :

V lt g
Voltage : 198 VDC

LOAD CYCLE :

Continuous Load (A2) : 36.76 Amps for 178 Min

First Minute Load (A1) : 111.53
111 53 Amps for 1 Min
Last Minute Laod (A3) : 62.65 Amps for 1 Min

BATTERY CAPACITY :

Cell selected : 300.00

300 00 AH
Charging Duration : 8 Hr.
CHARGER TYPE :

Float cum Boost Charger Dual Parallel Redundant

CHARGER RATING: :

The Charger shall be sized for one of the following duty conditions whichever is higher

1 Offline
1. Offli boost
b t charging
h gi g off the
th battery
b tt y assembly.
bly

Charger rating = Float charger rating or 15% of = 45 00

45.00 AMPS
battery AH capacity

2 Online
2. O li float
fl t charging
h gi g off the
th battery
b tt y assembly
bly while
hil feeding
f di g the
th complete
pl t DC load
l d
Where, Average DC Load = Area Under the Battery Duty Cycle / Battery Duty Cycle Duration
Charger rating =Continuous load requirement+Float charging current of battery(1
battery(1.5
5 mA/Ah of Battery)
= 3 21
37.21 AMPS

SEELCTED RATING FOR THE BATTERY CHARGER : 50 00

50.00 AMPS

Page 7 of 7