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Battery Sizing Design Basis TCE

This document provides design guidelines for DC power systems, including recommendations for: - Selecting between lead-acid and NiCad battery types - Choosing appropriate DC voltage levels for power plants and industrial facilities - Sizing battery capacities based on load requirements - Installing batteries and associated equipment like chargers It discusses factors to consider for sizing batteries, such as load profiles, discharge rates, and voltage levels. Guidelines are provided for typical battery installations in large power plants, industrial facilities, and other applications.

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Battery Sizing Design Basis TCE

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SECTION: TITLE

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SHEET ( i ) OF (v)

DC SYSTEM

DESIGN GUIDE
FOR
DC SYSTEM

TATA CONSULTING ENGINEERS

73/1, ST. MARKS ROAD
BANGALORE 560 001

FLOPPY NO
FILE NAME

: TCE.M6-EL-FP-DOC-006
: M6-6000.DWG

REV.NO

ISSUE

INITIALS

SIGN

INITIALS

SIGN

INITIALS

SIGN

PPD.BY

CPS

Sd/-

RRN

Sd/-

RRN

Sd/-

CKD.BY

DKB/DDRC

Sd/-

APP.BY

DKB

Sd/-

UAK

Sd/-

UAK

Sd/-

DATE

92-09-04

97-03-31

INITIALS

SIGN
R3

99-03-02
FORM NO. 020R2

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SECTION:
REV. STATUS

SHEET (ii ) OF (v)

DC SYSTEM

REVISION STATUS
REV. NO

DATE

99-03-02

DESCRIPTION

1.Design guides for Lead Acid

battery-(M6-EL-BT-6000 R2),NiCad
battery (M6-EL-BT-6000A R1) and
battery
Chargers(M6-EL-BC-6004
R2) have been combined to make a
composite design guide on the DC
System.
2. In addition the loads considered
for emergency lighting , auxiliary
relays and indicating lamps have
been revised.
3.Section
4.0
providing
recommendation for quantities of
batteries in different installations has
been revised.

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CONTENTS

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SHEET (iii) OF (v)

DC SYSTEM

CONTENTS
PART-A
LEAD ACID BATTERY
SL.NO.
1.0

TITLE
SCOPE

SHEET NO.
2

2.0

TYPES OF LEAD ACID CELLS

3.0

SELECTION OF DC VOLTAGE LEVELS

4.0

QUANTITIES OF BATTERIES

5.0

AMPERE HOUR CAPACITY SIZING

6.0

INSTALLATION OF BATTERY

7.0

REFERENCES

APPENDIX-1 TYPICAL EMERGENCY LOADS

APPENDIX-2 RATING AND DESIGNATION

CAPACITIES AND DIMENSIONS OF TUBULAR CELLS

CAPACITIES AND FINAL CELL VOLTAGE OF HDP

TUBULAR CELLS AT VARIOUS RATES OF
DISCHARGE AT 27deg.C

CAPACITIES AT 27deg.C AT VARIOUS RATES OF

DISCHARGE OF TYPE II HDP CELLS (TUBULAR)

PERFORMANCE CURVES TYPE-II HDP CELLS

(TUBULAR)

CAPACITIES AND DIMENSIONS OF PLANTE CELLS

APPENDIX-3 BATTERY SIZING - SAMPLE CALCULATION

APPENDIX-4 TYPICAL BATTERY ROOM PLAN

SAMPLE WORK SHEET

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CONTENTS
PART-B
NICAD BATTERY
SL.NO.
1.0

TITLE
SCOPE

2.0

DIFFERENT TYPES OF NICAD CELLS

3.0

PERFORMANCE CHARECTERISTICS

4.0

APPLICATIONS OF NICAD BATTERIES

5.0

MODE OF OPERATION

6.0

NUMBER OF CELLS

7.0

OTHER CONSIDERATIONS FOR SIZING NICAD

BATTERIES

8.0

INSTALLATION

9.0

BATTERY SIZING CALCULATIONS

10.0

SPECIFYING THE BATTERY

11.0

REFERENCES

APPENDIX-1 CELL DESIGNATION

SHEET NO.
35

PREFERRED DIMENSIONS

DISCHARGE DATA FOR NICAD BATTERY

(L,M & H TYPE CELLS)

TEMPERATURE CORRECTION
FACTOR CURVES
APPENDIX-2 SAMPLE CELL SIZING CALCULATION
CELL SIZING WORK SHEET

64
67
69

APPENDIX-3 COMPARISION OF NICAD BATTERIES

WITH LEAD ACID BATTERIES

SAMPLE WORK SHEET

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CONTENTS
PART-C
BATTERY CHARGER
SL.NO.

TITLE

SHEET NO.

1.0

SCOPE

2.0

RECOMMENDED PRACTICE

3.0

DISCUSSION

4.0

ENCLOSURES
i)
FLOAT CUM BOOST
CHARGER WITH
2 x 100% BATTERIES
ii)

iii)

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

FLOAT CUM BOOST

CHARGER WITH
1 x 100% BATTERY

TCE.M2-EL-CW-S-2632 R0

FLOAT AND BOOST

CHARGER WITH
1 x 100% BATTERY

TCE.M2-EL-CW-S-2633 R0

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PART A : LEAD ACID BATTERY

PART-A
LEAD ACID BATTERY

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1.0

SCOPE
This design guide outlines the recommendation for the determination
of voltage level, capacity, quantities and installation of DC battery of
lead acid storage type required for providing DC power supply to
essential services in the plant when the normal power supply fails.
This also gives consideration to the safe shut down of the plant as
well as human safety.

1.1

This section (Part A) of this guide pertains to lead acid batteries and
also includes a few recommendations applicable to NiCad batteries
also like selecting voltage levels. The sizing criteria for Nickel
Cadmium batteries are dealt in Part B of this design guide and
Part C of this guide covers details about Battery chargers .

2.0

VARIOUS TYPES OF LEAD ACID CELLS

2.1

The plante type cells are more rugged, need less maintenance and
have a life expectancy of about 15-18 years, which is 5-7 years
longer than that for tubular type. However, the plante type battery is
costlier than the tubular type. All the manufacturers make tubular
cells while very few manufacturers make plante cell.

2.2

The cells with tubular plate construction are smaller in size than the
plante type for a given AH rating.

2.3

The following types of tubular cells are available in the market in

addition to standard variety :
a)
b)
c)

High Discharge Performance (HDP)

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

2.4

The capacity of HDP cells under short duration discharge conditions

are higher than that of normal tubular batteries and are comparable to
that of Plante type batteries. Hence the capacity of battery required
will be smaller than that with the standard performance cells for
applications requiring high discharge currents for short duration.
Hence these cells are preferred for power plant applications.

2.5

The MF-VR cells require minimal attention from operation /

maintenance staff and are stated to need no topping up of distilled
water and no regular equalising charges. This type is well suited in
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the plants where organised maintenance is infrequent. The low

maintenance cells have grids made of low-antimony lead and require
topping up only once in a year or so even at higher float voltages like
2.25 VpC. Hence this type also is well suited for plants where
organised maintenance is infrequent or standalone substations in the
distribution system or medium or small scale industries or where
battery capacity is less than 300/500 AH.
2.6

The operating experience of the MF-VR and LM type cells for large
capacities is limited and very few manufacturers make the same.
Hence the sizing of these cells is not being discussed in the present
guide and use of these cells may be decided on case to case basis.

2.7

The recommended float voltage for lead acid batteries is between

2.16 V and 2.25V/ cell. The recommended boost charging duration is
10 hours in case of smaller capacity batteries and 14 to 16 hours for
larger capacities (1000 AH and above). The recommended maximum
boost charger voltage is 2.75 V/cell. The recommended equalising
charge voltage is 2.33 VpC.

3.0

SELECTION OF DC VOLTAGE LEVELS

3.1

The voltage level selection for the plant shall consider the following
aspects :

3.2

Quantum of power

Individual load point power ratings, quantum of such load points

and the geographic spread of the load points

Standard voltages suitable for the equipment

For the same power requirement, the battery room size, and battery
cost with higher voltage will be higher than those with lower voltage.
However, the lower voltage requires higher current for the loads and
hence to meet this current and to limit the voltage drop within limits
cable sizes will be higher than those with higher voltage. Considering
all the aspects following voltage levels are recommended.

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3.2.1 Power Plant

3.2.1.1 Large power plants (Coal based)
a)

For electrical power,

control & protection
requirements

I&C system

Normally most of the I&C

vendors' systems are suitable
for +24V or 48V DC.The
voltage level shall be fixed
after I&C system requirement
is finalised.

Isolated auxiliary plants

30 V DC or 110 V DC like raw

water pump house (dedicated
battery if running lengths of
cables from the main plant is
comparatively much higher)

Switchyards

220 V DC (If switchyard has

got separate control building)

Coal handling plant

110 V DC/220 V DC

3.2.1.2 Gas based/diesel/Hydro

110 V/220 V DC power plants

including captive power
plants

3.2.2

220 V DC

Industrial Plants
a)

Large plants with many

load points and distributed
in large area

220 V DC

Small plants with

multiple load points and
outdoor substations

110 V DC

Small plants with very

few switchboards / load points

30 V DC

For process control

Generally 24/48V (As

required by the I&C system
design)

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4.0
4.1
4.1.1

4.1.2

QUANTITIES OF BATTERIES
Power Plants
a) In case of unit sizes upto 250 MW, each unit shall be provided
with one battery and also, a separate battery shall be provided
for the common services of these units and switchyard load. The
unit and common services batteries shall be sized to cater one
unit and station service loads so that one serves as a standby to
the other.
b)

For instrumentation and control system two 100% batteries for

each unit shall be provided.

If switchyard is having a separate control building one 100%

battery shall be provided for the switchyard. In addition
switchyard DCDB will be provided with a tie feeder from station
DCDB (as a standby).

One no. 100% rating battery shall be considered for coal

handling plant DC power requirements.

For large power units (500 MW and above) and nuclear power plants,
for each unit, the 220V DC unit loads shall be divided into two
categories, e.g.
a)

D.C. power loads comprising D.C. motor drives, solenoids,

emergency lighting , etc.

D.C. control loads comprising tripping and closing circuits,

indicating lamps, protection and control panels, safetysupervisory systems etc.

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

and battery charger system. There will be three 50% rated
batteries.Each battery is capable of catering to 50 % power loads of
unit ( since the power load requirement of 500MW unit is very huge )
and entire control load of unit. Normally two of the three batteries will
cater power loads and the third one will be catering control loads.
For switchyard load there will be a seperate 100% battery feeding
switchyard loads.It is recommended to provide a tie from DCDB of
control loads to DCDB of switchyard. One number 100% battery shall
be considered for coal handling plant DC power requirement.

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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 to
have each unit battrery rated to cater two gas turbine units.and a tie
feeder is provided between one unit DCDB to another unit DCDB.
The station and STG DC loads shall be catered by provision of
2X100% batteries .
If switchyard and station building is seperate from the main plant
control building a seperate 1X 100% dedicated battery shall be
recommended.
For catering I&C loads , it is recommended to have 2X 100% rated
batteries for each unit.

4.1.4

Separate batteries with chargers are required to be provided for UPS

for power plants. For details please refer to design guide M6-CL-AUG-715-6011 for UPS.

4.2

Industrial Plants and Small Power Plants

Two 1X 100% rated batteries to cater for all the emergency power,
control and protection requirements of the plant. Shall be provided.
However, it shall be firmed up based on the quantum of the load
points and their geographic location.
A separate battery may be required for instrumentation, control and
annunciation requirement for process purposes. The specific
requirements in each case shall be ascertained.
Separate batteries with chargers are required to be provided for UPS
for Industrial and Small power plants. Possibility of using the same
station battery for UPS as well may be explored on a case to case
basis.

4.3

The recommendations on quantities are included int Part C of this

design guide in Tabular form.

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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 V
per cell. The capacity is a function of number of positive plates per
cell.

5.2

The battery capacity is influenced by the factors listed below.

a)
b)
c)
d)
e)

5.2.1

Duty cycle
End of the duty cycle voltage
Temperature correction factor
Compensation for ageing
Design margin

Duty cycle
a)

At the time of power supply failure, the battery is required to

supply D.C. power requirements of essential circuits for safe
shut down of the station, vital instrumentation, controls,
communication system, DC annunciation and emergency
lighting.

In power plants and some industrial plants an emergency diesel

generator is available, which will provide a.c. power to the
battery charger after the period required to start and connect it
to the emergency AC bus. However, the battery size shall be
calculated on the assumption that the engine driven generator
may fail to start or operate satisfactorily.

The duration for which each type of D.C. load will have to be
supplied by battery when the normal power supply fails is
different. The same may be continuous or for short time duration
or momentary. In a typical power plant the DC power, control &
protection loads and their classification based on duration for
which they need to be supplied are as follows.
Time duration
i)

Upto 1 minute

Loads (Amperes)
*

Trip relay / Trip coil currents of

circuit breakers.

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Starting currents of all

automatically started D.C.
motors.

DC motor operated emergency

steam stop valves.

Solenoid valves for isolation,

safety relief, minimum
recirculation etc.

Inrush currents of supervisory

safety system for fuel, turbine
and generator controls.

ii)

Upto one(1) hour

*
*
*

Emergency oil pump

Jacking oil pump
Steam generator control panels
(including FSSS, Mill panels)

iii)

Upto two(2) hours

*
*
*
*
*

D.C. seal oil pump

Scanner air fan
D.C. emergency lighting
P.A. system
Annunciation (20%)

iv)

Upto 10 hours

*
*

Indicating lamps / Semaphore

indicators in switchgears/control
panels
Control room emergency lighting
Annunciation (10%)
Auxiliary relay ( which are likely
to be energized during black out
condition )

A table of loads indicating their power requirement and duration

shall be prepared and a load curve for the battery shall be
established. Appendix-1 indicates a table for typical emergency
DC loads. Appendix-3 indicates a list of equipment and their
typical D.C. loads for a 210 MW unit. It is recommended that
project specific loads for DC motors, T.G. & S.G. vendor loads
and inrush currents shall be obtained before proceeding with the
sizing.

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5.2.2

I&C battery for power plant application shall be sized to cater

the loads for half hour. The loads to be considered shall be the
maximum load of I&C system at any operating condition viz
starting, running and tripping/stopping.

End of duty cycle voltage

The allowable end of duty cycle voltage of a battery has a major

role in determination of the capacity of the battery. This in turn is
dependent on the limits of system voltages that can be
withstood by D.C. equipment. The D.C. equipment are generally
rated to operate between +10% and -15% of their rated value
with certain exceptions like trip coils and trip relays which can
accept lower voltages.

Manufacturers recommend a float voltage ranging from 2.06V to

2.3 volts per cell, for different float voltage adopted, the required
frequency of equalising charges are given below.
-----------------------------------------------------------------------------------Float Voltage Per Cell
Approximate
periodicity of
equalising charges
----------------------------------------------------------------------------------2.25
No equalising charges
2.20
12 months
2.15
3 months
2.10
1 month
2.06
2 weeks
---------------------------------------------------------------------------------

It is desirable to keep the float voltages as high as the D.C.

system can accept to minimise frequency of equalising charges.
It is recommended to keep a float voltage of 2.2V per cell.
However, this shall be confirmed from the battery supplier
specific to the project.
i)

ii)

Considering the above, the number cells of a battery are

selected as :
Max.allowable DC voltage - Regulation due to charger
--------------------------------------------------------------Float voltage per cell
The end of duty cycle cell voltage is determined
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by
Min. allowable D.C. voltage + Cable drop
------------------------------------------------No. of cells
d)
Sl.
No
1

Typical values for 220V DC system and 24V DC systems are

given in the table below:
System
Max.allow Min.allowable No.of End of duty cycle
voltage
cells
voltage
able
voltage
220V
242V
187V
108
1 min - 1.75V /
cell 1,2 HRS &
10 hours 1.85V/cell
24V
30V*
21.5V*
13
1.8V/cell

* To be ascertained on project to project basis

Note : For 110V & 30V plant DC systems, the details can be worked
out in the same manner as for 220V system above.

5.2.3

The cable drop to be considered in DC system shall be 2% from

the charger/battery to Distribution board and 3% from board to
any feeder in case of 220V DC system.

In case of 24V DC system to keep the voltage drop

within 5% limit, the cable sizes between DC board and I&C
cabinets are very large and sometimes impractical to terminate.
Hence for 24V system a total drop of 7.5% (2.5% between board
and charger/battery and 5% between board and individual
loads) is recommended.

Temperature correction factor

The standard temperature for stating cell capacity is 27deg.C. If the
lowest expected electrolyte temperature is below 27deg.C, a cell
large enough to have the required capacity available at the lowest
expected temperature shall be selected. The lowest electrolyte
temperature shall be considered as 10o above minimum ambient
temperature. If the lowest expected temperature is above 27deg.C,
no correction factor shall be applied. The correction factor shall be
calculated according to the formula:
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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. The
minimum electrolyte temperature (T) shall be considered as 10deg.C
higher than the minimum ambient air temperature at site.
5.2.4

Compensation for age

ANSI/IEEE STG.450-1270 recommends that a battery be replaced
when its actual capacity drops to 80% of its rated capacity. Hence a
factor of 1.25 shall be considered for ageing.

5.2.5

Design margin
When the D.C. loads are more or less final at the time of battery
sizing for tender specification purposes and/or the battery sizing is
being done for a similar plant already executed, no design margin is
considered necessary. If the sizing is being done for a new type of
project or with very little confirmed loads, a design margin of 10 to
15% shall be provided over the final capacity arrived.
While sizing the battery for nuclear power plant applications, it shall
be noted that the "margins" required by IEEE STD.323-1273. 6.3.15
& 6.3.3 are to be applied during "Qualification" and are not related to
"design margin".

5.3

Calculation of Ampere Hour Capacity

The plante and tubular high discharge performance cells have better
capacity factors at the short duration discharges (1 hour, 2 hours
etc.). For durations less than one hour, the above types of cells have
higher capacity factor than the tubular standard discharge
performance cell. Hence for power plant application and for
applications where short duration loads are appreciable high
discharge performance cell shall be used.
The capacity of the battery shall then be determined in accordance
with the procedure outlined in Appendix-3.

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6.0

INSTALLATION

6.1

Battery cells shall be installed in a separate battery room, preferably

near the D.C.load. The 24V batteries shall be in the same floor as
I&C cabinets and as near as possible. Fig.4 included in design guide
TCE.M6-EL-PJ-G-SG-6602 R1 (GA of Turbine Building Electrical
Equipment & Space Organisation) indicates a typical battery Room
Plan (Copy of Fig.4 enclosed as Appendix-4 for ready reference).

6.2

The flooring shall be provided with acid resistance tiles, a dished

floor drain and drainage piping for collecting spilled acid. The spilled
acid shall be diluted before discharging to the outside storm water
drainage system.

6.3

Acid proof paint shall be provided on walls upto 2.3m height.

6.4

A wash basin shall be provided for emergency drenching of face and

body.

6.5

The total capacity of exhaust fans (suitably distributed) should be

minimum 1/10th of the total volume of the battery room per minute.
The exhaust shall be directly outside the building. However, specific
requirements shall be obtained from the battery manufacturer.

6.6

Separate cable(s) shall be provided for each polarity of the outgoing

battery leads. If the cables are unarmoured they shall be taken in
separate conduits and the conduits shall be PVC coated for
protection against corrosion. Routing of any cables in cable-trays
through battery room shall be avoided.

6.7

Adequate provision for storage of acid, distilled water, instruments,

accessories, etc. should be provided in the battery room.

6.8

During float or boost charging of the lead acid battery hydrogen gas
is generated. The volume of hydrogen gas generated depends on the
amount of charging current. Also, the float current demand of a fully
charged battery will double approximately for every 10deg.C rise
above the base temperature of 27deg.C. Each fully charged cell
produces 4.5 x 10-4 Cu.m (0.016 Cu.pt) hydrogen gas per hour per
charging amperes in an ambient of 25deg.C to 27deg.C. Hydrogen
explosive concentration is reached if the explosives mixture is three
percent of the volume of room air.

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6.9

In view of the presence of hydrogen gas, warning signs shall be

installed outside and inside the room prohibiting smoking, sparks of
flame.

6.10

Lighting fixtures shall be vapour-proof type with reflectors painted

with anticorrosive epoxy-paint. Lighting switch should be outside the
battery room.

7.0

REFERENCES

7.1

IS:1651-1991

Stationary cells and batteries,lead-acid type

with Tubular positive plates Specification.

7.2

IS:1652-1991

Stationary cells and batteries, lead-acid

type with Plante' positive plates
Specification.

7.3

IEEE Std 485-1273 :

Recommended practice for sizing large lead

acid storage batteries for Generating
Stations and Sub-stations.

7.4

IS:8320-1272

General requirements and methods of tests

for lead-acid storage batteries

7.5

IS:1885-1965

Electrotechnical vocabulary Secondary cells and batteries.

7.6

IEEE Std. 450-1270 :

Recommended practice for maintenance

testing and replacement of large lead
storage batteries for generating stations and
sub-stations.

7.7

IEEE Std. 484-1271 :

Recommended practice for Installation

design and installation of large lead storage
batteries for generating stations and substations.

7.8

IEEE Std. 323-1273 :

IEEE Standard for Qualifying class-1E

Equipment for Nuclear Power Generating
Stations.

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APPENDIX - 1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SHEET

DC SYSTEM

OF 79

PART A : LEAD ACID BATTERY

APPENDIX-1
TYPICAL EMERGENCY LOADS

a) Bearing oil pump

b) Bearing oil pump for BFPT
c) Bearing oil pump for MBFP

STEAM TG
500MW
120MW
13kW
15kW
2x5.5kW --11kW
---

a) Seal oil pump

b) Seal water pump for BFPS

13kW
60kW

10kW
---

11kW
---

Jacking oil pump

35kW

37KW

28KW

Scanner air fan

----

4.4KW

7.5KW

Inverter for instruments

5kW

10kW

Inverter for PA system

2kW

Carrier panels

<-----------

Auxiliary relay (each)

<-----------

150watt/ --------->
panel
3watts
--------->

Auxiliary contactor (each)

<-----------

10watts

--------->

DC emergency lights

<-----------

Approx.
10% of
normal
lighting

--------->

UPS load (Incl. DAS,

transmitters, controllers)

55kVA

45KVA

30kVA

210MW
13kW
-----

ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX - 1
SHEET

OF 79

PART A : LEAD ACID BATTERY

APPENDIX-1 (Contd)
TYPICAL EMERGENCY LOADS

500MW

STEAM TG
120MW
210MW

Continuous Loads
Annunciator window (each)

Indicating lamp (each)

-----5-10W For filament type ----

----1 W For cluster LED type type ---

Auxiliary relays (each)

<--------------------3W--------------------------

Auxiliary contactors (each)

<--------------------10W-----------------------

Semaphore indicator (each)

<--------------------3W------------------------

Control room emergency

lighting

<---------------------1kW---------------------

FSSS load

-------------------10kW---------------------

---------------------5W -----------------

NOTES:
1.

The data for 120MW and 210MW units are taken from the designed
data for GIPCL and Bhatinda units. All DC motor loads,
electromagnetic valve loads, FSSS loads, instrumentation & control,
UPS loads, other turbine generator supervisory loads should be as
far as possible ascertained from the manufacturers.

When starting currents of DC motors are not available it may be

assumed as 3.5 x FL current. If step resistor starting is provided the
starting current may be assumed as 2.5 x FL current.

Instrumentation and control loads and annunciation loads may be on

a separate 48 V / 24V battery.

For 210 MW unit loads also refer Appendix-3.

ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SECTION:
APPENDIX-2
SHEET

DC SYSTEM

OF 79

PART A : LEAD ACID BATTERY

APPENDIX-2
CELL DATA
RATING AND DESIGNATION
1

Ampere-Hour Rating
The rating assigned to the cell shall be the capacity expressed in
ampere-hours (after correction to 27deg.C) stated by the
manufacturer to be obtainable when the cell is discharged at the 10hour rate (C10) to a final voltage of 1.85 voltage.

Designation
The cell shall be designated by symbols given below, arranged in the
following sequence :
Type of Positive
Plate
(See 2.1)

Ah Rating
of Cell
(See 2.2)

Type of
Container
(See 2.3)

Notes:
1.

The plates are not replaced in this type of construction

therefore, this designation does not include the number of
positive plates; and

The designation of partially plated cells is not being

standardized because partial plating of cells in this type of
construction is not done.

2.1

The positive plates shall be designated by the letter 'T' for tubular
and 'P' for plante.

2.2

The capacity rating shall be indicated by a number equal to the

capacity in Ah.

2.3

The material of container shall be designated by any one of the

following letters as the case may be :
G - for glass;
H - for hard-rubber;
P - for plastics;
ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-2
SHEET

OF 79

PART A : LEAD ACID BATTERY

W - for wood, lead-lined; or

F - for fibre reinforced plastics (FRP)
Example : T 400H HDP - designates a high discharge performance
cell having tubular positive plates and a capacity of 400 Ah at 10 hour
rate in hard-rubber container. SOURCE : IS 1651 & 1652 - 1991

ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-2
SHEET

OF 79

PART A : LEAD ACID BATTERY

APPENDIX-2 (Contd)
CELL DATA
Capacities and Dimensions of
Tubular Cells
----------------------------------------------------------------------------------------------Capacity at
Maximum Overall Dimensions
10-Hour Rate ---------------------------------------------------------------------Length
Width
Height
(1)
(2)
(3)
(4)
Ah
mm
mm
mm
--------------------------------------------------------------------------------------------20
105
170
365
40
105
170
365
60
140
170
365
80
165
190
365
100
190
190
450
120
190
190
450
150
190
190
550
200
265
215
550
300
320
215
550
400
380
215
550
500
390
235
550
600
390
235
715
800
515
235
715
1000
515
300
750
1500
450
400
865
2000
500
450
865
2500
650
450
865
4000
900
480
1240
5000
900
480
1240
6000
900
500
1240
7000
1100
500
1240
8000
1100
500
1240
--------------------------------------------------------------------------------------------NOTES :
1.

The length and width dimensions given in this table may be

interchanged.

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

the interconnector shall be disregarded.
ISSUE
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FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-2
SHEET

OF 79

PART A : LEAD ACID BATTERY

For capacities not covered in this table, the cell dimensions shall
not exceed the dimensions of the cell of next higher size covered
by this table.
SOURCE : IS 1651 - 1991
APPENDIX - 2 (Contd)
Standard Discharge Performance Cells (Tubular)

Capacities and Final Cell Voltage

at various rates of discharge at 27deg.C
------------------------------------------------------------------------------------------Period of Capacity Ratio :
Capacity
Final
Discharge Ah capacity (CT)
Rating Factor
Cell
Hours (T) divided by the 10hr (KT) = (1/2)
Voltage
Rated capacity (C10)
(Volts)
(1)
(2)
(3)
(4)
--------------------------------------------------------------------------------------------1
0.500
2
1.75
2
0.633
3.16
1.78
3
0.717
4.18
1.80
4
0.782
5.12
1.81
5
0.833
6.00
1.82
6
0.879
6.83
1.83
7
0.917
7.63
1.83
8
0.950
8.42
1.84
9
0.979
9.19
1.84
10
1.0
10
1.85
-------------------------------------------------------------------------------------------Source : IS 1651-1991

ISSUE
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FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SECTION:
APPENDIX-2
SHEET

DC SYSTEM

OF 79

PART A : LEAD ACID BATTERY

APPENDIX - 2 (Contd)
CELL DATA
Capacities at 27deg.C at various rates of discharge
Type II High Discharge Performance (HDP) Cells (Tubular)
------------------------------------------------------------------------------------------------Period of Capacity Ratio :
Capacity
Final Remarks
Discharge Ah capacity (CT)
Rating Factor Cell
Hours (T) divided by the 10hr (KT) = (1/2) Voltage
Rated capacity (C10)
(Volts)
(1)
(2)
(3)
(4)
------------------------------------------------------------------------------------------------1/60 (1 min)
0.022
0.76 1.75 } M/s Chloride
1/2 (30 min)
0.368
1.36 1.75 } India
1

0.60
0.488
0.392

1.67
2.05
2.55

1.75
1.80 } M/s Chloride
1.85 } India

0.738
0.714
0.597

2.71
2.80
3.35

1.78
1.80 } M/s Chloride
1.85 } India

0.811

3.77

1.80

0.862

4.13

1.81

0.90

5.55

1.82

0.93

6.45

1.83

0.951

7.361 1.83

0.971

8.239 1.84

0.988

9.109 1.84

10
1.0
10.0 1.85
---------------------------------------------------------------------------------------------Source : IS 1651-1991 & Capacity Rating curves from M/s Chloride India.
NOTE : The above data is applicable for plante cells also. The capacities for
Type-I HDP cells are same as above for discharge rates of 3 hour, 5
hour and 10 hours (ISS does not specify capacities at other
discharge rates for Type-I cells).

ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-2
SHEET

OF 79

PART A : LEAD ACID BATTERY

TYPICAL CELL PERFORMANCE CURVES (SH-1)

ISSUE
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FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-2
SHEET

OF 79

PART A : LEAD ACID BATTERY

ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-2
SHEET

OF 79

PART A : LEAD ACID BATTERY

APPENDIX - 2 (Contd)
CELL DATA
Capacities and Dimensions: Plante Cells
----------------------------------------------------------------------------------Capacity at
Maximum
Overall
Dimensions
10-Hour Rate ---------------------------------------------------------Length
Width
Height
(1)
(2)
(3)
(4)
Ah
mm
mm
mm
----------------------------------------------------------------------------------20
130
140
225
40
205
140
225
60
205
140
225
80
175
235
370
100
175
235
370
120
175
235
370
150
175
235
370
200
210
235
370
300
290
235
370
400
365
235
370
500
375
310
625
600
375
310
625
800
375
335
625
1000
385
375
635
1500
520
390
635
2000
650
390
635
2500
785
405
130
4000
1160
405
130
5000
1350
515
650
----------------------------------------------------------------------------------NOTES :
1.

The length and width dimensions given in this table may be

interchanged.

For capacities not covered in this table, the cell dimensions shall
not exceed the dimensions of the cell of next higher size covered
by this table.
Source : IS 1652-1995

ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-3
SHEET

OF 79

PART A : LEAD ACID BATTERY

BATTERY DUTY CYCLE DIAGRAM

L
4
=
9
0
0
A

L6 = 84 A

L5 = 186 A

L3 = 46A

L2 = 30A
L1 = 13 A
SECTION-1

120

600

SECTION-2
SECTION-3
SECTION - 4
DURATION ( MIN )

ISSUE
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FORM NO. 120 R1

SECTION:
APPENDIX-3

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SHEET

DC SYSTEM

OF 79

PART A : LEAD ACID BATTERY

APPENDIX - 3
SAMPLE CALCULATION FOR SIZING OF A THERMAL POWER
STATION 220V UNIT BATTERY (210 MW)

LOAD TABULATION
Sl.
no

Load description

Qty.

Rating
Watts

1 min

1 hr.

UNIT LOADS

Tripping loads ( Prot. Relay + Trip Relay + CB Trip coil )

6.6 kV CBs

300

10,200

415 V CBs

250

1,750

Turb. Generator

E.O.P.

13,000

32,500*

13,000

DC seal oil pump

11,000

27,500*

Jacking oil pump

28,000

70,000*

28,000

Others

2,000

Steam generator

10,000

2hrs.

10 hrs.

11,000

10,000

DC CSP (includes
FSSS, mill panel)
4.

Main steam stop

valve

4,000

10,000

Scanner air fan

7,500

18,750 *

7,500

Emergency lighting

5000

Indicating lamps

400

Annunciation
windows

Auxiliary relays

1000
400

100

50
600 (200
nos @ 3W
each )

ISSUE
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FORM NO. 120 R1

SECTION:
APPENDIX-3

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SHEET

DC SYSTEM

OF 79

PART A : LEAD ACID BATTERY

STATION LOADS

Tripping loads
6.6 kV CBs

300

21,000

415 V CBs

250

3,000

Indicating lamps

500

1 #

PA system

Auxiliary relays

500
2,000
300
(100 nos
@3W
each )

TOTAL AMPS

894

232

116

*
#

Starting currents of motor ( 2.5 times the rated current )

Cluster LED type indicating lamps

2.0

SIZING CALCULATION

2.1

Battery duty cycle diagram in Sh.24 is constructed as detailed below

from the above DC emergency load list for a typical 210 MW unit.

2.2

Analysis of load data in Sh.25&26 indicates the distribution of loads

with duration as under :
Load

Sl.
no

Duration

0 10 hrs.

2850 W

13A

1 min. - 2 hrs.

(11000+7500) =18500W

84A

0 2 hrs.

(5000-1000) + (100- 50) +

2000 = 6500W

30A

1 min. - 1 hr.

(28000+13000) = 41000 W

186A

0 1 hr.

(51000 -(13000+28000))
=10000 W

46A

0 - 1 min.

196680 W

894A

In Watts

in Amperes

NOTE: These loads are arrived at taking care to see that loads are not
ISSUE
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FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-3
SHEET

OF 79

PART A : LEAD ACID BATTERY

repeated under the same time duration , for example in (0-1hr) load
duration the load would be (51000-(13000+28000))=10000,
(13000+28000) being subtracted from the total load as the same is
already considered under (1minute -1hr )load.
2.3

The cell sizing data that will be useful in filling out the cell sizing work
sheet is derived from the duty cycle diagram and tabulated as below :
Cell sizing data
--------------------------------------------------------------------------------period
Loads
Total Amperes
Duration (min)
---------------------------------------------------------------------------------

2.4

1.
L1+L2+L3+L4
983
1
2.
L1+L2+L3+L5+L6
359
59
3.
L1+L2+L6
127
60
4.
L1
13
480
-------------------------------------------------------------------------------Capacity rating factors (KT) are derived from the table for HDP, Type
II tubular lead acid cells enclosed in Appendix-2. (These can be read
from the curves enclosed in Appendix-2 also).

2.5

Sh.29 &30 shows the way in which the cell sizing work sheet and the
KT rating factor would be used to size the battery for the duty cycle
indicated.

2.6

Design margin
Considered as 1.0 since the loads for 210 MW thermal power plant
are well established.

2.7

Temperature correction factor :

Minimum ambient temperature for the installation is 7deg.C. Hence,
the lowest expected electrolyte temperature to be considered (in
accordance with cl.5.2.3) is 17deg.C (=7deg.C+10deg.C)
Temperature correction factor to be applied
0.43 (27-17)
= 1 + ----100
= 1.043

ISSUE
R3
FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-3
SHEET

OF 79

PART A : LEAD ACID BATTERY

NOTES :
1.

Tubular cell type HDP-II is considered in the above sample

calculation as the duty requires the cells to deliver high discharge in
short duration (1 hr). However, the same procedure as above can be
followed for sizing the battery using HDP Type-I or standard
discharge performance cells. Data on cell capacities at varying
periods of discharge for standard discharge performance type cells &
for Type-I HDP cells is enclosed in Appendix-2.

If plante cells are being sized, the data on capacities for Type II HDP
cells enclosed in Appendix-2 can be used sizing procedure also
remains same except the value of 'K' in formula for temperature
correction factor (Refer cl.5.2.3).

Typical DC emergency loads for a 210 MW unit are considered for

the sample calculation above. In case the load cycle diagram for a
particular installation happens to be more complex than the one in the
sample calculation above, IEEE 485-1273 may be referred for further
guidance.

ISSUE
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FORM NO. 120 R1

SECTION:
APPENDIX-3

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SHEET

DC SYSTEM

OF 79

PART A : LEAD ACID BATTERY

Project :

Date :

Lowest Expected
Electrolyte Temp : 17oC

(1)

Period

(2)

Load
(Ampe
res)

Minimum 1 Min.:1.75V DC
Cell Voltage : Others: 1.85V DC

Cell Chloride
Mfg. : India

Cell Tubular
Type : HDP, Type-II Sized By : RRN

(3)

(4)

(5)

(6)

(7)

Change in
Load
(Amperes)

Duration
of Period
(minutes)

Time to
End of
Section
(minutes)

Capacity
at T Min.
rate
K Factor
(KT)

Required Section Size or

(3)x(6B) = Rated AH

Pos Values

Neg.Value

LOAD DATA :
A1= 983 A,
M1= 1 Min;
A2 = 359 A,
A3= 127 A,
M3= 60 Min;
A4 = 13 A,
A5= A,
M5= Min; A6 = A, M6 = Min.

M2 = 59 Min.
M4 = 480 Min.

Section - 1: First Period only - If A2 is greater than A1, go to Section-2

1
A1=983
A1-0=983
M1=1
T=M1=1
Sec.-1

Section - 2: First Two Periods only - If A3 is greater than A2, go to Section-3

1
A1=983
A1-0=983
M1=1
T=M1+M2=60
2
A2=359
A2-A1= -624
M2=59
T=M2=59
Sec.-2

Section - 3: First Three Periods only - If A4 is greater than A3, go to Section-4

1
A1=983
A1-0=983
M1=1
T=M1+...+M3=120
2
A2=359
A2-A1= -624
M2=59
T=M2+M3=119
3
A3=127
A3-A2= -232
M3=60
T=M3=60
Sec.-3

Section - 4: First Four Periods only - If A5 is greater than A4 go to Section-5

1
A1=983
A1-0=983
M1=1
T=M1+...+M4=600
2
A2=359
A2-A1= -624
M2=59
T=M2+...+M4=599
3
A3=127
A3-A2= -232
M3=60
T=M3+M4=540
4
A4=13
A4-A3= -134
M4=480
T=M4=480
Sec.-4

Section - 5: First Five Periods only - If A6 is greater than A4 go to Section-6

1
A1=
A1-0=
M1=
T=M1+...+M5=
2
A2=
A2-A1=
M2=
T=M2+...+M5=
3
A3=
A3-A2=
M3=
T=M3+...+M5=
4
A4=
A4-A3=
M4=
T=M4+M5=
5
A5=
A5-A4=
M5=
T=M5=
Sec.-5

0.76
Total

747
747

2.55
2.55
Sub Total
Total

2507

3.35
3.35
2.55
Sub Total
Total

3293

10
10
9.1
8.2
Sub Total
Total

9830

2507
916

3293
611

9830
544

Sub Total
Total

***
***

1591
1591
***

2090
592
2682
***

6240
2111
935
9286
***

***

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

ISSUE
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FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-3
SHEET

OF 79

PART A : LEAD ACID BATTERY

Section - 7: Random Equipment Load only (if needed)

R
AR=
AR-0=
MR=

T=M+R=

Section - 8:
Maximum Section Size = 916

Section - 9:
Random Section Size = -

Section - 10:
Temperature Correction Factor = 1.043

Section - 11:
Design margin = 1.0

Section - 12:
Aging Factor = 1.25

Section - 13:
Uncorrected size = (8) + (9)= 916+ - = 916

Section - 14:
All capacity required = (13) x (10) x (11) x (12) = 916 x 1.043 x 1.0 x 1.25 = 1193 AH

Section - 15:
When AH capacity required is larger than the nearest standard cell, the next larger size cell is required.

Section - 16:
Therefore AH capacity of the cell = 1200 AH

ISSUE
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FORM NO. 120 R1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

DC SYSTEM

SECTION:
APPENDIX-4
SHEET

OF 79

PART A : LEAD ACID BATTERY

TYPICAL BATTERY ROOM LAYOUT

FOR DETAILS REFER HARDCOPY

ISSUE
R3
FORM NO. 120 R1

SECTION:
APPENDIX-4

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SHEET

DC SYSTEM

OF 79

PART A : LEAD ACID BATTERY

Project :

Date :

Lowest Expected
Minimum
Electrolyte Temp : oC Cell Voltage :

Cell

Mfg. :

Type :

Sized By :

(1)

(2)

(3)

(4)

(5)

(6)

Period

Load
(Amperes)

Change in
Load
(Amperes)

Duration
of Period
(minutes)

Time to
End of
Section
(minutes)

Capacity
at T Min.
rate
K Factor
(KT)

(7)
Required Section Size or
(3)x(6B) = Rated AH

Pos Values

Neg.Value

LOAD DATA :
A1=
A3=
A5=

A,
A,
A,

M1=
M3=
M5=

Min;
Min;
Min;

A2 =
A4 =
A6 =

A,
A,
A,

M2 =
M4 =
M6 =

Min.
Min.
Min.

Section - 1: First Period only - If A2 is greater than A1, go to Section-2

1
A1=
A1-0=
M1=
T=M1=
Sec.-1

Section - 2: First Two Periods only - If A3 is greater than A2, go to Section-3

1
A1=
A1-0=
M1=
T=M1+M2=
2
A2=
A2-A1=
M2=
T=M2=
Sec.-2

Section - 3: First Three Periods only - If A4 is greater than A3, go to Section-4

1
A1=
A1-0=
M1=
T=M1+...+M3=
2
A2=
A2-A1=
M2=
T=M2+M3=
3
A3=
A3A2=
M3=
T=M3=
Sec.-3

Section - 4: First Four Periods only - If A5 is greater than A4 go to Section-5

1
A1=
A1-0=
M1=
T=M1+...+M4=
2
A2=
A2-A1=
M2=
T=M2+...+M4=
3
A3=
A3-A2=
M3=
T=M3+M4=
4
A4=
A4-A3=
M4=
T=M4=
Sec.-4

Total

***
***

Sub Total
Total

***

Sub Total
Total

***

Sub Total
Total

***

Sub Total
Total

***

Section - 5: First Five Periods only - If A6 is greater than A4 go to Section-6

1
A1=
A1-0=
M1=
T=M1+...+M5=
2
3
4
5

A2=
A3=
A4=
A5=

A2-A1=
A3-A2=
A4-A3=
A5-A4=

M2=
M3=
M4=
M5=

T=M2+...+M5=
T=M3+...+M5=
T=M4+M5=
T=M5=
Sec.-5

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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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1.0

SCOPE
This section outlines the Ni-Cd alkaline station storage battery
performance characteristics, usage and sizing.

2.0

DIFFERENT TYPES OF Ni-Cd BATTERIES

2.1

The most common electrode design for the nickel-cadmium batteries

is the pocket plate type designated by 'P' as per IS:10918-1274. The
active constituents are cadmium in the negative plates and nickel in
the positive plates. The active material in each electrode is enclosed
in metal pockets of finely perforated steel strips. Each plate is
insulated from the next by thin plastic separators. The electrolyte is a
solution of potassium hydroxide in de-ionised water. The resulting
electrochemical reaction produces a nominal discharge voltage of 1.2
volts per cell. The electrolyte takes no part in these reactions and
acts only as an ion conductor. The other electrode designs are
sintered plate(s) and tubular plate(T).

2.2

The cells are further classified as H,M,L and X type based on the
discharge performance of individual designs. The plate type, and the
number of such plates employed in a cell indicate the cell type and
determine its discharge characteristics.

2.3

The cell container is usually translucent polypropelene

plastic.Polypropelene has high strength, it is corrosion free and not
electrically conductive. Cells can also be supplied in stainless steel
containers, if required, to with-stand conditions of high shock and
vibrations. Steel cells are mounted on wooden racks.

3.0

PERFORMANCE CHARACTERISTICS

3.1

The rated capacity C5 of any cell type is defined as available

amperehours (Ah) at 5 hours discharge rate at 27C, to an end
voltage of 1.0V/Cell after charging for 8 hours with 0.2C5 A. (In the
U.S. the Ni-Cd capacity is based on 8 hours discharge).
The standard ambient temp. specified by IS:10918 is 27C, whereas
the Ni-Cd batteries available in Indian market are rated at 20C +5C
ambient. The same is adopted in the design guide for the present.

3.2

Normal voltage is 1.2V/Cell

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3.3

Open circuit voltage is 1.28 V/Cell.

3.4

The measure of performance is not the rated Ah capacity but the

battery cell construction. H type cells have thin plates (more plate
area per amount of active material) giving excellent high rate
performance. M and L types have medium thickness plates and thick
plates respectively. For example H-type cell at 15 minutes discharge
can deliver about twice the discharge current compared to an L-type
cell of equal rated capacity.

3.5

The published discharge data for nickel-cadmium cells are most

commonly available in tabular form, in which the current, available
from each cell type, is stated for a given discharge time and end of
discharge voltage. For intermediate times and voltages, it is
necessary to interpolate between the known values (IEEE 11151992).

3.6

There are three manufacturers in India, AMCO (in collaboration with

SAFT,France), SABNIFE POWER SYSTEMS LTD., Hyderabad in
collaboration with M/s Sabnife, Sweden and Punjab Power Packs Ltd.
in collaboration with M/s Alcad Ltd. UK. The available tabulated
discharge performance data from M/s SABNIFE on different types of
cells for varying end cell voltages, is enclosed at Appendix-1.(The
cell designations of Sabnife make cells confirm to IS.S10918-1274).
More details if required, may be obtained from the manufacturers.

3.7

EFFECT OF TEMPERATURE
Battery optimum performance is based on cell electrolyte temperature
maintained at 20-25C. For temperatures below 20C a loss of about
0.5% of rated capacity per C is expected for Ni-Cd battery. No
increase in capacity is to be considered above 20C. The derating
curves enclosed in Appendix-1 can be used for arriving at the
derating factors appropriate to the lowest expected electrolyte
temperature for the individual installation.
Example:
Cell Type
Cell end Volt
Discharge time
Min. Ambient temperature
Lowest expected electrolyte temp.

: KPM100P
: 1.1 V
: 30 mins
: 0C
: 0+10C ( Ref. Clause 5.2.3
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of Part A of this design guide )

: 0.925

Temp. derating factor

(From enclosed curves)
Available current at 10C = 101A

(Data from performance table

at 20-25C) x 0.925 = 93.425A

3.7.1

Life of the battery is shortened when temperatures are above the

reference temperature of 25C. Generally it has been estimated that
Ni-Cd battery loses approximately 15% of its life for every 8-10C
electrolyte temperature above 25C.

3.8

CHARGING REQUIREMENTS
To fully charge, a cell will require an Ah input, from the charger to the
battery, of 160% of the capacity. For example a 100Ah cell requires
160 Ah to fully charge it from a fully discharged state. If the charger
can supply 20A then the time for charging will be 160/20 i.e. 8 hours.

3.9

Cell Data :
Type-L

Type-M

Type-H

a) D C internal resistance,
ohms

0.20x(1/C5) 0.15x(1/C5) 0.06x(1/C5)

b) Maximum Short circuit

current, A

10xC5

15xC5

25xC5

3.10

The electrolyte specific gravity (S.G.) is not an indication of the state

of charge in Ni-Cd cells since it does not change appreciably during
charge or discharge. The acceptable limits to be maintained in normal
service (of the electrolyte S.G) are 1.17-1.19 at a reference
temperature of 20 at the specified level line of the cell.

3.11

Indian Standard 10918-1274 specifies the general requirements and

methods of test for Ni-Cd batteries. This is derived from IEC Pub 6231978.

4.0

APPLICATIONS OF Ni-Cd BATTERIES

Some typical applications of different battery (Cell) types (X,H,M,L)
are mentioned herewith for their optimum usage.
Applications of very high rates of discharge batteries (Type X) are to
deliver very large currents (>7C5) for very short durations (1 Sec-15
min).

4.1

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4.2

Applications of High rate (H type) batteries are to deliver high

currents (>3.5C5 A) for very short discharge times of 20 mins and
less. Typical uses are
- Engine starting (gen-sets, fire pumps, locomotives, vehicles)
- Some applications of Uninterruptible power supply (UPS).
- Switch closing, electromagnets.
In such cases the capacity of the battery is not so important as the
ability to deliver high current.

4.3

Medium rate (M type) applications are load duties having discharge

times between 3 hours to 30 min, for examples:
- UPS for A.C process control
- Electric train control
- Off-shore applications
- Combined discharge cycle like switchgear operation, standby
pumps and emergency lighting.(Typically medium rate of discharge
usage is between 0.5C5A and 3.5C5A).

4.4

Low rate (L type) applications are of power requirements for an

extended discharge time of 3 hours and longer.
Example are:- Telecommunications and signalling
- Scada/Computer system
- General standby applications for power stations/ industrial projects,
i.e. load cycle duty of switch trippings, emergency oil pumps,
emergency lighting, protection/controls annunciation, communication.
(Typically low rate of discharge usage is between less than 0.5C5A to
C5A).

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4.5

For applications where adverse conditions of usage prevail, (like

extremes of temperature, on regular routine maintenance and nonavailability of a separate battery room), Ni-Cd batteries are most
suitable for use because of their following special features.
a)

Tolerance of extremes of temperature. The manufacturers claim

the range from -50C to +55C. It is of advantage to use Ni-Cd
battery for cold temperature performance.

Maintenance requirements are very low for pocket plate Ni-Cd

batteries when operated as mentioned in clause 5.0 within the
range of 15C to 25C.

Overcharging even for a prolonged period is tolerated. Also,

these batteries can be left in discharged/partially discharged
conditions without damage.

Gases given off by Ni-Cd batteries are not corrosive and normal
building materials/room can be used and therefore the battery
can be kept in the electrical/mechanical equipment room, if it
becomes necessary to do so. However, adequate ventilation is
necessary as stated under installation (Clause 7.0).

5.0

MODE OF OPERATION

5.1

In the standby battery usage for continuous parallel operation with

rectifier, with occasional battery discharge, the recommended
charging values are as follows:
Charging in service:
a)

Float charge

1.4 - 1.42 V/Cell H,M,L

High rate (Boost)

charge

1.53-1.67 V/Cell for H type

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

Trickle charging current of :

fully charged cell

1.5 mA per Ah

Boost charging standard

0.4C5A for 8 hours,H,M,L

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Fast recharging

0.5C5A for 2.5 Hours followed

by 0.2C5A for 2.5 hours.

With float charging at 1.4-1.42 V/Cell and where the load

temporarily exceeds the
charger rating, it is beneficial to
apply an equalising charge every 6 to 12 months (depending
on use) to keep the battery up to a fully charged condition.

5.2

For use of batteries without any boost charge, the float charge
voltage is 1.47-1.5V pC for L type, 1.46-1.49V pC for M type and
1.45-1.47V pC for H type.

6.0

NUMBER OF CELLS
For the usual standard system voltages, the recommended number of
cells is as follows:

6.1
Nominal System Voltage
24
No. of Cells
For continuous operation with 19
float charging

110

220

37-38

84-86

168-172

6.2

The number of cells to be used for a specific project should be

checked considering the nominal system voltage, voltage tolerances,
charging voltage (i.e. mode of operation) and type of load (i.e.
discharge currents / time for given cell end - voltage). Based on these
factors the number of cells may vary from the number given above.

6.3

Recommendations on selection of voltage level and quantities of

batteries cells are provided at Clause 3.0 & 4.0 of Part A of this
design guide.

6.4

Example :
a)

Nominal system voltage 110V

All equipments are specified to operate satisfactorily at 80-110%

of rated DC voltage, except the DC motors which work
satisfactorily upto 85% of rated voltage.

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No. of cells 'n'

Allowable max. voltage for DC system = 110% of 110V = 121
volts
Float voltage to be selected = 1.4 to 1.42 V/Cell
With float voltage of 1.42 V pC and system voltage limit of 121
volts.

No. of cells required of 110V rated DC system

121
= ---- = 85.2 or 85 cells.
1.42
Cell end voltage :
Allowable min. voltage for DC system
85% of 110V at equipment terminals = 93.5 volts.
Considering a max. voltage drop of 5% in the system,
Allowable min. voltage at battery terminals = 90% of 110V = 99
volts.
99
Thus permissible cell end voltage =---- = 1.16 volts
85

7.0

OTHER CONSIDERATIONS FOR SIZING Ni-Cd BATTERIES

In addition to the above factors, factors like design margin, ageing
factor also influence the final size of the battery selected.

7.1

Design Margin :
This is to allow for unforeseen additions to the dc systems and less
than optimum operating conditions of the battery due to improper
maintenance, recent discharge or ambient temperatures lower than
anticipated. This shall be decided on case to case basis. The cell
size calculations for a specific application will seldom match a
commercially available cell exactly and it is normal procedure to
select the next higher size cell. The additional capacity obtained thus,
can be considered part of the design margin. While sizing battery for
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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 applied
during "qualification" and are not related to "design margin".
7.2

Ageing Factor :
Capacity decreases gradually during the life of the battery, with no
sudden capacity loss being encountered. Since the rate of capacity
loss is dependent upon such factors as operating temperature,
electrolyte sp.gravity, and depth and frequency of discharge, an
ageing factor should be chosen based on required service life. The
choice of ageing factor is, therefore, essentially an economic
consideration. IEEE recommends a factor of 1.11 for batteries used
for UPS wherein the discharges are for a short time and 1.43 for
applications involving continuous high temperatures and/or frequent
deep discharges.

7.3

State of Charge Factor :

When the batteries are subjected to discharge and then charge, they
get charged gradually. The state of charge at any point depends on
the initial state of charge, the recharge voltage, the charge current
limit and the charging voltage. The state of charge factor can be
determined by consulting the charging curves provided by Battery
manufacturers and shall be considered if the selected float charge
voltage is 1.47-1.50V (Ref. item 5.2 above).

7.4

Float Charge Factor :

When batteries are expected to remain in continuous float charge for
prolonged periods without boost charge, they exhibit a dip in
performance depending on end voltage and duration of discharge.
The cells float charged at 1.4-1.42V pC (Ref item 5.1 of above) are
not expected to lose much charge if the schedule for equalising
charges is adhered to. Hence no provision is made for float charge
factor in cell sizing calculations.

8.0

INSTALLATION

8.1

Ni-Cd battery can be installed in a separate room or in the same room

as the electrical/mechanical equipment since the gases given off are
not corrosive. However, a separate room specially for large size
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batteries would be preferable. The typical battery room layout is

enclosed in Part A of this design guide for information.
8.2

Though Ni-Cd batteries are tolerant of extremes of temperature, it is

preferable to operate within the range of 15C to 25C to optimise
efficiency. Direct sunlight and heat on cells should be avoided.

8.3

Hydrogen and oxygen evolved from a battery during charge can form
an explosive mixture. For this reason adequate ventilation is to be
provided to keep the hydrogen content to a low value. The maximum
gas evolution occurs at end of charge or on overcharge. Since
hydrogen is lighter than air, openings/grilles to take away the gas
mixture should be located as high as possible in the room.
Following formula is given by the Manufacturers for a mean hydrogen
concentration of 1%.
Air changes required
per hour

1.47xFinal charge(amps)xNo. of cells

Room air Vol.in Cu.ft

If forced ventilation is found necessary to obtain the required air

changes per hour, the air should be drawn from a high location in the
room. When calculating air changes in confined spaces it will be
necessary to deduct the volume of other apparatus and the battery.
9.0

BATTERY SIZING CALCULATIONS

The method to be used for sizing Ni-Cd battery is same as explained
in PARTA of this DC System Design guide .

9.1

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

9.2

The factor KT related to the specified end cell voltage and load
duration is readily available for lead-acid cells. But for Ni-Cd cells,
this shall be computed from the discharge data tables (enclosed at
Appendix-1). Wherever the required data is not available, it can be
interpolated/extrapolated from the known values (Refer item 3.5
above).
Select the cell type most suited to the duty profile required (Ref. item
4.0).

9.3

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

expected minimum electrolyte temperature and read the temperature
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correction factors corresponding to the cell type selected and specific

discharge duration, for the above temp, from the relevant curves
enclosed in Appendix-1.
9.4

Divide the load currents specified by the temperature correction

factors corresponding to the specified duration to obtain the load
currents corrected to 25C.

9.5

Select the cell size, looking at the discharge tables, that can meet the
short duration load current requirements.

9.6

Crated
Calculate the capacity rating factors ( KT = ------- ; t = duration )
It
for different load currents & corresponding durations as above, from
the discharge tables.

9.7

Follow the worksheet (Blank form enclosed in Appendix-3) and

determine the cell size. Apply ageing factor, design margin etc. (in
accordance with item 7.0 above) to arrive at final cell size.

9.8

Sample cell sizing calculation is included in Appendix-2.

10.0

SPECIFYING THE BATTERY

It is observed that the discharge data available from different
manufacturers for a given type and AH rating of cells differs
considerably at durations other than nominal duration (5 hours).
Hence it is recommended that while specifying the battery, the
following may be noted.

10.1

Load profile, required end cell voltage, factors to be considered and

other data shall be provided to the bidder and the bidder is allowed to
offer cell size other than the one indicated (determined by TCE
through cell sizing calculations as above) providing the supporting
calculations.

10.2

Bidder may be allowed to offer cell type other than the one indicated,
if the offered cell type & size meets the load cycle duty requirements
satisfactorily (bidder to establish the same through supporting
calculations). This is being recommended as many a time the load
profile consists of mixed type of loads (ie. of different durations) and
thus more than one type (but with different ratings) can meet the
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requirements satisfactorily.
11.0

REFERENCES

11.1

TCE.M6-EL-718-6000 'Station battery- Lead Acid' Design Guide.

11.2

IS:10918-1274 Specification for vented type Ni-Cd batteries.

11.3

Technical Data from M/s SABNIFE.

11.4

IEEE 1115-1992 IEEE Recommended Practice for sizing NickelCadmium Batteries for Stationary applications.

11.5

IEEE : 1106-1277 IEEE Recommended practice for maintenance,

testing and replacement of Nickel-Cadmium storage batteries for
Generating Stations and Substations.

11.6

IEEE : 323-1273 IEEE Standard for qualifying class IE equipment for

Nuclear Power Generating Stations.

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APPENDIX-1
CELL DESIGNATION
Vented nickel cadmium prismatic rechargeable cells shall be
designated by the letter 'K' followed by a second letter referring to the
positive plates:
T for cells with tubular plates,
P for cells with pocket plates, and
S for cells with sintered plates.
The second letter shall be followed by a third letter:
L for low rate of discharge (below 0.5 C5),
M for medium rate of discharge (between 0.5 C5 and 3.5 C5),
H for high rate of discharge (between 3.5 C5 and 7 C5), and
X for very high rate of discharge (above 7 C5).
The group of three letters shall then be followed by a group of figures
indicative of the capacity of the cell in ampere-hours, for example
KSH 185. Cells in cases of plastic material shall be marked with the
letter "p" after the figures, for example KSH 185 P.
Source : IS:10918-1274

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APPENDIX-1 (contd)
PREFERRED DIMENSIONS
TABLE :

THESE DIMENSIONS ARE VALID FOR OPEN NICKEL

CADMIUM PRISMATIC CELLS IN STEEL CONTAINERS AND
PLASTIC CONTAINERS

STEEL CONTAINERS
PLASTIC CONTAINERS
Max. Width. (b)in Max. Height (h) in Max. Width. (b) Max. Height (h) in
mm
mm
mm
in
mm
81
291
62
178
105
350
81
241
131
409
87
273
148
409
123
273
157
409
138
273
188
409
147
285
--165
406
--173
375
--195
406
NOTE 1 --

The dimensions, given in Table 1, represent preferred values.

NOTE 2 --

The widths relate to the overall width dimension of the cell

excluding the thickness of the lug flanges.

NOTE 3 --

The maximum height relates to the total height dimensions over

terminals or closed cell valves. The data for heights given in
table are maximum values, no lower limits being stated.

NOTE 4 --

It is not possible to make proposals for length dimensions (d) at

this stage.

NOTE 5 --

The dimensions shown in Table 1 are not coupled to particular

cell capacities. The apply to all kinds of open prismatic nickelcadmium cells, such as L,M,H, and X types.

Source : IS:10918-1274

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KPL RANGE
TYPICAL CELL PERFORMANCE DATA ( 20o C + 5o C )
Discharge data is for full charged cells after 1 hour open circuit and allowing for voltage losses associated with connectors.

AMPERES ON DISCHARGE TO 1.00 VOLT PER CELL

CELL
TYPE

CAP
(Ah)

SECONDS

MINUTES

HOURS

KPL5P
KPL11P
KPL19P
KPL29P
KPL39P
KPL49P
KPL60P
KPL70P
KPL75P
KPL90P
KPL100P
KPL130P
KPL155P
KPL190
KPL220P
KPL250P
KPL280P
KPL320P
KPL350P
KPL380P
KPL410P
KPL440P
KPL480P
KPL500P

5
11
19
29
39
49
60
70
75
90
100
130
155
190
220
250
280
320
350
380
410
440
480
500

11.8
25.9
44.7
68.3
93.6
120
138
157
177
204
231
283
337
389
440
486
531
579
628
675
723
750
805
916

9.7
21.4
37
56.5
76.8
96.6
115
131
150
171
193
236
282
327
373
413
453
496
539
581
624
654
713
808

8
17.7
30.5
46.6
62.9
80
96.5
111
118
137
156
192
213
258
308
346
377
409
442
473
505
570
615
676

6.6
14.5
25
38.1
51.3
67.7
81.8
90.5
94.9
108
123
150
182
230
244
274
300
326
351
378
406
483
525
566

5.9
12.9
22.3
34
45.5
59.8
72.5
79.4
82.8
93.1
105
131
158
186
214
241
265
290
315
339
363
443
482
514

4.6
10
17
26.7
35.9
45.1
55.2
61.7
65
74.8
85.7
108
124
147
172
197
222
246
271
296
321
368
400
428

3.5
7.7
13.3
20.3
27.3
34.3
42
48.3
51.7
61.
71.4
89.6
107
129
150
171
193
215
236
258
279
297
323
352

2.8
6.2
10.6
16.2
21.8
27.4
33.6
38.6
42
49.5
57.1
71.7
87.9
106
124
141
159
177
194
212
230
243
254
278

2.3
5
8.6
13.1
17.6
22.1
27
31.1
34.2
40.1
45.9
57.6
70.7
85.1
99.5
113
128
142
156
171
185
199
216
227

1.6
3.5
6.1
9.3
12.5
15.7
19.2
22.1
24.3
28.5
32.6
41
50.2
60.5
70.7
80.6
90.9
101
111
121
132
141
154
162

1
2.2
3.8
5.8
7.8
9.8
12
14
15
18
20
26
31
38
44
50
56
64
70
76
82
88
95
100

0.6
1.4
2.4
3.7
4.9
6.2
7.6
8.7
9.5
11.2
12.9
15.1
19.8
23.8
27.8
31.8
35.8
39.8
43.7
47.8
51.8
55.4
61.2
64.4

0.5
1.1
1.9
2.9
3.9
4.9
6.1
7
7.7
9
10.3
12.9
15.9
19.1
22.3
25.3
28.7
31.9
35
38.3
41.5
45.5
49.4
52

KPL580P
KPL655P
KPL730P
KPL810P
KPL885P
KPL960P
KPL1100P
KPL1210P
KPL1320P
KPL1440P

580
655
730
810
885
960
1100
1210
1320
1440

1030
1150
1270
1390
1500
1610
1900
2080
2250
2410

914
1020
1120
1230
1330
1420
1690
1840
1992
2140

768
860
955
1050
1140
1230
1430
1570
1710
1840

644
722
801
880
966
1050
1200
1320
1450
1570

596
678
743
808
886
964
1090
1210
1330
1440

490
552
612
672
736
800
912
1010
1100
1190

400
448
494
540
594
646
729
810
891
969

319
360
402
446
487
528
605
666
726
792

261
295
329
365
398
432
495
545
594
648

186
210
234
259
283
307
352
387
422
461

116
131
146
162
177
192
220
242
254
288

74
83.5
93.1
103
113
122
140
154
168
184

59.7
67.5
75.2
83.4
91.2
98.9
113
125
136
148

ISSUE
R3
FORM NO. 120 R1

SECTION:
APPENDIX-1

TATA CONSULTING ENGINEERS

TCE.M6-EL-7186000

SHEET

DC SYSTEM

OF 79

PART B : NICAD BATTERY

KPL RANGE
TYPICAL CELL PERFORMANCE DATA ( 20o C + 5o C )
Discharge data is for full charged cells after 1 hour open circuit and allowing for voltage losses associated with connectors.

AMPERES ON DISCHARGE TO 1.02 VOLT PER CELL

CELL
TYPE

CAP
(Ah)

KPL5P
KPL11P
KPL19P
KPL29P
KPL39P
KPL49P
KPL60P
KPL70P
KPL75P
KPL90P
KPL100P
KPL130P
KPL155P
KPL190
KPL220P
KPL250P
KPL280P
KPL320P
KPL350P
KPL380P
KPL410P
KPL440P
KPL480P
KPL500P

5
11
19
29
39
49
60
70
75
90
100
130
155
190
220
250
280
320
350
380
410
440
480
500

11.1
24.4
42.2
64.3
88
113
130
147
167
192
218
267
318
367
415
453
500
546
592
637
683
706
757
875

9.2
20.2
34.9
53.3
72.2
91
108
124
140
160
181
222
264
307
350
388
425
463
502
540
578
628
674
762

7.5
16.6
28.7
43.8
58.9
75.2
90.5
104
112
128
145
182
215
251
288
322
351
383
414
445
476
537
579
638

6.2
13.5
23.4
35.7
48.4
63.5
76.7
84.8
88.9
101
115
139
169
198
227
255
279
304
331
354
380
452
491
532

5.5
12.1
20.9
32
43.4
56.5
68.1
74.4
77.5
86.9
98.6
122
147
173
199
224
247
272
298
321
344
416
452
482

4.4
9.7
16.6
25.7
34.8
43.9
53.5
59.4
62.4
71.3
81.8
102
119
142
165
188
211
235
259
282
306
351
381
406

3.4
7.5
13
19.8
26.7
33.5
41
47.2
49.9
58.7
68.1
85.5
103
123
144
164
185
206
227
247
268
286
311
337

2.7
6
10.4
15.9
21.4
26.9
32.9
37.8
41
48.2
55.5
69.6
85.4
103
120
137
154
172
189
206
224
237
258
271

2.2
7.9
8.4
12.9
17.3
21.8
26.6
30.6
33.7
39.5
45.3
56.8
69.7
83.9
98.1
112
126
140
154
168
182
196
213
223

1.6
3.5
6
9.2
12.4
15.5
19
21.9
24.1
28.2
32.3
40.6
49.7
59.9
70
79.8
90
100
110
120
130
139
151
159

1
2.2
3.8
5.7
7.7
9.7
11.9
13.9
14.8
17.8
19.8
25.7
30.7
37.6
43.6
49.5
55.4
63.4
69.3
75.2
81.2
87.1
95
99

.6
1.4
2.4
3.6
4.9
6.1
7.5
8.6
9.5
11.1
12.8
16
19.7
23.7
27.7
31.6
35.5
39.5
43.4
47.5
51.5
56.5
60.9
64.1

0.50
1.1
1.9
2.9
3.9
4.9
6
6.9
7.6
8.9
10.2
12.9
15.8
19
22.2
25.3
28.5
31.7
34.8
38.1
41.3
45.3
49.2
51.8

KPL580P
KPL655P
KPL730P
KPL810P
KPL885P
KPL960P
KPL1100P
KPL1210P
KPL1320P
KPL1440P

580
655
730
810
885
960
1100
1210
1320
1440

979
1086
1198
1310
1412
1514
1792
1960
2118
2266

862
964
1060
1162
1254
1344
1594
1740
1883
2020

724
810
899
988
1073
1158
1346
1478
1610
1735

603
675
750
826
904
982
1124
1236
1354
1470

554
627
693
760
832
904
1030
1138
1246
1352

462
519
581
642
702
759
872
963
1050
1134

382
426
474
522
576
621
709
784
859
932

311
349
391
435
474
513
591
649
708
771

257
290
323
359
391
424
487
536
584
638

183
206
230
255
279
302
347
381
416
454

115
130
145
160
175
190
218
240
261
285

73.5
83.1
92.5
103
112
122
140
154
163
183

59.5
67.1
74.8
83
90.7
98.4
113
124
135
143