Switchgear Battery Sizing by Hand

Switchgear Battery Sizing by Hand
By Aaron J. Hall, P.E., CH2M HILL, Inc.

Apr 1, 2006 12:00 PM
A refresher on how to size batteries sans software

Sizing battery banks for switchgear and control applications is
commonly performed using software designed specifically for that
purpose. Just input the required load profile, and the program
selects the optimum battery configuration. Although this is quite
simple, an engineer should be capable of performing a
straightforward hand calculation either to confirm the results of a
software-generated solution or to serve as an accurate design for a
simple battery system.
Do you know how to perform these calculations by hand? If not,
then read on. This article will help you understand the basic
premise of sizing switchgear battery systems and provide an
example calculation for clarification of the concept. IEEE Standard 485-1997, Recommended
Practice for Sizing Lead-Acid Batteries for Stationary Applications, also provides detailed guidelines
for battery sizing.
Number of cells
Battery banks for switchgear and control applications are

made up of many cells. These cells are typically wired in
series to achieve a desired voltage and may also be wired
in parallel to achieve additional ampere capacity. Sizing of
these battery banks, therefore, includes selecting the
number and type of cells to be used.
The terminal voltage per cell varies with the battery's
chemical composition. The required number of series
wired cells to achieve the more common DC control
voltages for switchgear control is shown in Table 1.
Selection of the type of cell is based on the required peak
ampere output and total Ampere-hour (Ah) output
capacity for the load and duration.
Link to Document
Table 1
Load type
IEEE Standard 485-1997 classifies individual DC loads as continuous, non-continuous, and

momentary. Typical continuous loads include lighting, continuously energized coils, and power to
protective relay and communications systems. Non-continuous loads are less common and include
critical ventilation system motors and valve actuators with operating times exceeding 1 minute.
Momentary loads do not exceed 1 minute in duration and include inrush currents and circuit breaker
operations.
The duty cycle imposed on switchgear batteries usually consists of momentary high ampere loading
during charging of the respective tripping or closing springs, in addition to the small continuous load
of powering protective relays and lights.
While both motors for charging the tripping or closing springs can be DC, the more common
switchgear design uses an AC closing motor and a DC tripping motor. Such a design reduces the
total DC load because tripping is of the utmost importance particularly when a fault occurs.
However, this only allows one full operational cycle following a power failure because there is no AC
to charge the closing spring.
Sizing guidelines
Since the momentary load on a switchgear battery bank is much higher than the continuous load,
the required 1-minute (peak) ampere rate typically determines the battery cell type. However the
Ampere-hour rate should also be checked. The battery cell type that meets the worst-case condition
between the two should be selected.
These rates are tabulated in the manufacturer's standard literature at several final voltages. Use the
rates published at a final voltage of 1.75 volts-per-cell for lead acid cells or 1.14 volts-per-cell for
nickel cadmium cells. As an example, the data in Table 2 on page 43 is excerpted from a
manufacturer's Web site. (The model designations are fictitious.)
Link to Document
Table 2
To calculate the required 1-minute ampere rate, assume the peak rate to be equal to the sum of the
loads (i.e. in-rush current for all breaker charging motors, load currents for all relays and other
loads, and ignore pilot lights).
Although momentary loads usually exist for much less than a minute perhaps only a fraction of a
second it is common practice to use the full ampere value for an entire minute. Assign a required
1-minute rate equal to this peak rate divided by the ambient temperature derating factor, the
battery aging factor, and a design margin as listed in Table 3 on page 43.
Link to Document
Table 3
To calculate the required Ampere-hour rate, compute the average continuous load and divide by the
ambient temperature-derating factor and battery-aging factor, as listed in Table 3. Use the
manufacturer's data to select the battery cell type that meets both the ampere and Ampere-hour
requirements.
Sample calculation
To use a hypothetical real-world example, calculate the battery size for the 69kV substation loads
listed in Table 4. The battery type shall be lead acid, operate the given loads for 8 hours at
125VDC, and be housed in a climate-controlled building.
Link to Document
Table 4
Step 1: Calculate the required 1-minute discharge rate.
As can be seen in Table 4, the peak discharge rate is 96.2A. Divide this number by an ambient
temperature factor of one for a 77F room, by a 0.8 battery-aging factor, and by 0.85 for the design
margin.
Required 1-minute discharge rate = 96.2 A 0.8 0.85 = 141.5A
Step 2: Calculate the required Ampere-hour (Ah) rate.
As can be seen in Table 5, the total Ampere-hour rate is 27.1 Ah. Divide by an ambient
temperature factor of one for a 77F room, and by a 0.8 battery-aging factor.
Required total Ah rate = 27.1 Ah 0.8 = 33.9 Ah
Link to Document
Table 5
Step 3: Select the appropriate cell from the manufacturer's literature.
Referring back to Table 2, a Model A battery has a 1-minute discharge rate of 177A and an 8-hour
Ah rate of 180 Ah, down to 1.75V. This type of battery is, therefore, more than sufficient for this
particular load. The 125VDC, 180 Ah battery bank would be composed of 60 Model A cells.
Back to basics
So whether you're one of those people that refuses to trust a computer farther than you can throw
it or you simply feel more comfortable double checking calculations by hand possessing the
knowledge to size battery banks for switchgear the old-fashioned way is a good skill for any
engineer to master. Not only will you impress your peers, but you'll also feel more confident about
recommending a rock solid switchgear solution.
Hall is an electrical engineer based in the Las Vegas office of CH2M HILL, Inc.
Table 1. String together 37 individual Ni-Cad batteries in series to achieve a control voltage of 48V.
Battery Type
Control Voltage
Ni-Cad
Lead acid
48VDC
37 cells
125VDC
92 cells
24 cells
60 cells
250VDC
184 cells
120 cells
Table 2. Ampere-hour and ampere rates for four different battery models offered by one
manufacturer.
Nominal Rates at 77F (25C)

Final Volts
Models
Ampere-Hours
(Ah)
4-hr
8-hr
1.75V
Amperes (A)
3-hr
1.5-hr
1-hr
30 min
15 min
1 min
180
142
132
65
81
109
134
177
250
210
195
98
126
172
219
303
330
280
260
130
168
230
292
404
410
350
326
163
204
285
362
500
Table 3. Design factors to be used when calculating Ampere-hour rates for Ni-Cad and lead-calcium
batteries.
Battery Type
Derating Function
Ni-Cad
Lead-Calcium
Ambient temperature
77F
1.0*
1.0*
32F
0.7
0.67
0F
0.5
0.8
Battery aging factor
0.8*
0.8*
Design margin
0.85*
0.85*
*Per IEEE Std. 485 recommended practice
Table 4. Peak discharge rate for a hypothetical 69kV substation load.

125VDC Load Description
Quantity
Current (A)
Subtotal (A)
69kV circuit switchers
15.0
30.0
69kV substation relays
0.2
1.6
5kV vacuum breakers
7.0
63.0
5kV switchgear relays
0.2
1.6
5kV switchgear indicating lights
Ignore
0.0
0.0
Total
96.2A
Table 5. Required Ampere-hour rate for a hypothetical 69kV substation load.

125VDC Load Description
Quantity
Current (A)
Hours (h)
Subtotal (Ah)
69kV circuit switchers
15.0
0.016*
0.5
69kV substation relays
0.2
8.0
12.8
5kV vacuum breakers
7.0
0.016*
1.0
5kV switchgear relays
0.2
8.0
12.8
5kV switchgear indicating lights
Ignore
0.0
8.0
0.0
Total
*0.016 hours = 1 minute
27.1 Ah

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Switchgear Battery Sizing by Hand

By Aaron J. Hall, P.E., CH2M HILL, Inc.

A refresher on how to size batteries sans software

Battery banks for switchgear and control applications are

IEEE Standard 485-1997 classifies individual DC loads as continuous, non-continuous, and

Nominal Rates at 77F (25C)

Battery aging factor

*Per IEEE Std. 485 recommended practice

Table 4. Peak discharge rate for a hypothetical 69kV substation load.

69kV circuit switchers

69kV substation relays

5kV vacuum breakers

5kV switchgear relays

5kV switchgear indicating lights

Table 5. Required Ampere-hour rate for a hypothetical 69kV substation load.

69kV circuit switchers

69kV substation relays

5kV vacuum breakers

5kV switchgear relays

5kV switchgear indicating lights

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