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CONTRACT AM-CO630
6305-EL-MCA-7050-A00
AC & DC AUXILIARY SERVICES CALCULATION REPORT
MAITENES DISCHARGE ZONE
Modifications:
6305-EL-MCA-7101-A00
AC & DC SYSTEM CALCULATION REPORT
LAS LAJAS SURFACE WORK
ALFALFAL DISCHARGE CHANNEL
MODIFICATION
INDEX
1. INTRODUCTION .................................................................................................. 4
2. SCOPE ................................................................................................................. 4
3. PURPOSE ............................................................................................................ 5
4. REFERENCE LIST ............................................................................................... 5
4.1 Codes and Standards ................................................................................. 5
4.2 Project Documents ..................................................................................... 5
4.2.1 Basic Engineering Documents ....................................................... 5
4.2.2 Basic Engineering Drawings .......................................................... 6
4.2.3 Detailed Engineering Documents ................................................... 6
4.2.4 Detailed Engineering Drawings ...................................................... 6
5. SERVICE CONDITIONS....................................................................................... 6
6. DESIGN CRITERIA .............................................................................................. 6
6.1 Alternating Current Equipment.................................................................... 7
6.2 Direct Current 24 VDC Equipment .............................................................. 7
7. CALCULATION METHODOLOGY ....................................................................... 7
7.1 General considerations ............................................................................... 7
7.2 Loads Type Definition ................................................................................. 8
7.2.1 Alternating Current Load ................................................................ 8
7.2.2 Direct Current Load ........................................................................ 8
7.3 Power Transformer Selection ..................................................................... 9
8. SHORT CIRCUIT SIZING ..................................................................................... 9
8.1 Short Circuit in Alternating Current - Low Voltage (220 VAC) ..................... 9
8.2 Short Circuit in Direct Current - Low Voltage (24 VDC) .............................. 9
8.2.1 Rectifier charger contribution ....................................................... 10
8.2.2 Battery Banks Contribution .......................................................... 10
8.2.3 Total short circuit current at 24 VDC ............................................ 11
8.3 Nominal Current in Bars ........................................................................... 11
9. BATTERY SIZING .............................................................................................. 11
9.1 Definition ................................................................................................... 11
9.2 Cycle Duty Definition ................................................................................ 11
For sizing DC battery sets; we will represent the operating cycle diagram in the
case of loss. That corresponds to voltage loss in 8 hours period. ............ 11
9.3 Battery Bank Cells Number Selection ....................................................... 12
9.4 Battery Capacity Determination ................................................................ 13
9.5 Battery Correction Factors ........................................................................ 14
9.5.1 Temperature Reduction Factor (Tt) .............................................. 14
9.5.2 Design Margin .............................................................................. 15
9.5.3 Aging Factor ................................................................................. 15
10. SELECTING THE BATTERY CHARGER ........................................................... 16
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AC & DC SYSTEM CALCULATION REPORT
LAS LAJAS SURFACE WORK
ALFALFAL DISCHARGE CHANNEL
MODIFICATION
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DISCHARGE CHANNEL MODIFICATION
1. INTRODUCTION
The Alto Maipo Hydroelectric Project (AM Project) will be located southeast of
Santiago City, in the municipal district of San Jos de Maip, Cordillera Province,
Metropolitan Region, specifically at the Maip River upper basin.
It includes the construction of two hydroelectric plants which are Alfalfal II and Las
Lajas, that are laid out in hydraulic series.
The AC and DC auxiliary services for the discharge channel modification at the
Alfalfal site will supply electric power for control and supervision of the
hydromechanical equipment and the corresponding actuators.
2. SCOPE
The low voltage alternating and direct current auxiliary services will be fed from a
distribution transformer connected to the existing 12 kV Maintenes-Alfalfal medium
voltage distribution line. This report takes into account the loads to be fed to
determine the size of the distribution transformer.
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3. PURPOSE
The purpose of this calculation report is to size the AC and DC auxiliary services
system according to document 600-SC-CDD-001.
4. REFERENCE LIST
International Standards
IEC 60529 : Degrees of Protection Provided by Enclosures (IP Code).
IEC 60439 : Low-Voltage switchgear and controlgear assemblies.
IEC 60896 : Stationary lead-acid batteries
IEEE Std. 485 : Recommended Practice for Sizing Large Lead Storage
Batteries for Generating Stations and Substations.
IEEE Std. 1188 : IEEE Recommended Practice for Maintenance, Testing,
and Replacement of Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary
Applications
IEEE Std. 1184 : IEEE Guide for Batteries for Uninterruptible Power
Systems
Switchgear Manual - Asea Brown Boveri, 11th edition.
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5. SERVICE CONDITIONS
The ambient environmental conditions for the transmission lines are as follows.
6. DESIGN CRITERIA
The main equipment selection is based on the following criteria:
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The rated voltage on the LV-side of the distribution transformer will be 400-230
V (at no-load condition).
The distribution transformer will be sized with an extra 15% reserve capacity.
The main circuits of the AC switchboard will be equipped with three-pole
molded-case circuit breakers (MCCB) and the switchboard will be equipped with
non-segregated busbars solidly grounded, five wires (3 phases + N + PE)
The AC switchboards will be provided with busbar voltage presence
signalization lamps.
The single-phase power outlet circuits will be equipped with single-pole 16, 20
and 25 A mini circuit breakers (MCBs), provided with 30 mA residual current
protection devices.
The Single-phase illumination circuits will be equipped with 16 A mini circuit
breakers (MCBs).
The AC switchboards will be provided with 25% reserve outputs circuits.
The rated short-circuit withstand current for switchboard busbar will be 14 kA-
peak(600-SC-CDD-001 item 05), 3 s at 380-220 V.
The AC switchboard will supply three-phase, five pins, 380-220 V power outlets
and single-phase, three pins, 220 V power outlets.
7. CALCULATION METHODOLOGY
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a) Load on the dc system exceeds the maximum output of the battery charger
b) Output of the battery charger is interrupted
c) AC power is lost [may result in a greater dc power demand than item b)]
The most severe condition will be considered to determine the battery size in terms
of its charge and duration.
Gear motor
Electric Lifting Motor
Electric Trolley Motor
Heating - Penstock
External illumination
Outlets: Single phase(1) and Three phase (3)
Battery charger
Illumination and heating Switchboard
Air Extractor Switchboard
Board feeder
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The total power for the auxiliary service transformer is calculated by adding all loads,
multiplied by simultaneity factor (fs), and divided the power factor (fp).
KVATransf .
Demandas fs
fp
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V * Xt pu *U 22
U 2 cc X 1
2 2 St
X total X t X f U2
Iccca
X TOTAL
Where:
Xtpu Short-circuit impedance for rectifier transformer (p.u.).
U2 Secondary voltage of rectifier transformer [Vca].
St Apparent power of rectifier transformer [kVA].
Xf . Rectifier filter inductance [H], typical 40 H.
Vcc Rectifier output voltage [24 VDC].
Iccca AC short-circuit current [A].
Icccc DC short-circuit current [A].
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S 3
In *
3 * VL L
9. BATTERY SIZING
9.1 Definition
Available capacity: A specific discharge time; and at the end voltage
discharge that can be removed from a cell under specific operating conditions.
Battery Duty Cycle: Charging a battery is anticipated for specified periods of
time.
Full Operating load (Constant Potential): the DC system operating with battery,
battery charger, and all loads connected in parallel to the battery normal DC
charger supply plus any self-discharge or any charge current required by the
battery. (The battery supplies power only when the load exceeds the charger
output).
Period: A time interval at working cycle during which the load is assumed to be
constant for cell size calculations.
For sizing DC battery sets; we will represent the operating cycle diagram in the case
of loss. That corresponds to voltage loss in 8 hours period.
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Section 1 (S1): After the fault, the opening coils of the switches from AC mainboard
auxiliary services (time 1 minute).
Section 2 (S2): After 5 minutes, switches disconnectors are opened to initiate
verification work.
Section 3 (S3): Closing switches to restore service after 8 hours with simultaneously
motors start.
Section 4 (S4): During this time: protection, control and measurement panels are in
operation.
I(A)
I1
S1 S3
S2
I2
S4
T (min)
0 1 5 6 479 e480
The selected cells are Lead-Acid type, with GEL type electrolyte, sealed, and
maintenance-free.
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The following formula is used to calculate the battery minimum voltage per cell:
Final Discharge Voltage = Minimum Battery Voltage
Number of cells
The battery capacity is calculated to supply current, during all operation cycles
established by sections.
From the graph, the capacity calculation for each section is:
For calculation purposes, the battery sizing factor can be expressed as:
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Then, applying iteratively the capacitance calculation for each section and replacing
the KT factor, we obtain the following relation to determine battery capacity in
amperes - hour (Ah).
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Capacity decreases gradually over the battery lifespan, with no sudden loss of
capacity occurring under normal operating conditions. Since the rate of loss capacity
depends on factors such as operation temperature, electrolyte specific gravity
,discharge depth and discharge frequency; an aging factor must be chosen based on
battery lifespan required ( See IEEE Std 485).
1.25 and replace the batteries when their capacity decreases to 80%.
1.43 and replace the batteries when their nominal capacity decreases to 70%.
For UPS an aging factor of 1.11 is recommended, and batteries should be
replaced when their nominal capacity drops to 90%.
The maximum load connected to it, plus necessary current to keep the battery bank
float voltage.
The necessary load current for the battery bank capacity, and the recharging time
required.
For rectifiers with UI curves and voltage limits of 2.23 V / cell, the required nominal
current is calculated as follows:
C r Ch f
I n Lc
Tr
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Where:
In : Nominal Current (A)
Tr : Charging time (h)
Cr : Required Capacity (Ah)
Lc : Charging current (A)
Chf : Battery charge factor
For design purposes; the switch and disconnector motor loads shall be considered as
permanent loads, so their simultaneity factor shall be applied.
The 24VDC Charger-rectifier should supply 100% loads in flotation, and provide
enough current to recharge their respective battery banks.
Also, simultaneity factor has been considered according to type and numbers of
equipment for each load; The factor will be 1.0 for all permanent loads considerate.
For 24 Vdc battery bank; the following permanent loads are considered:
HMI panel
Communications Panel N 1
Red Lan Board
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In our case, we will consider that each rectifier absorbs 100% of the normal load, and
has 8 hours recharge period.
11. CONCLUSIONS
From the alternating and direct current calculation for Auxiliary services, as well as
their 220 Vca and 24 VDC boards short circuit calculations, the following is
concluded:
Considering the project load (Distribution substation loads, gate load and its
equipment), the 12/0.23 kV auxiliary service transformer capacity shall be75
kVA.
The maximum short-circuit capacity for 220 VAC auxiliary services shall be 14
kA.
The capacity for 220 VAC auxiliary services general Board (TD MC) wont be
less than 630 A, for which a 20x5 mm painted copper bar is recommended.
The auxiliary service general board (TD MC) will be fed from 220 Vca transfer
board bar, which will supply AC loads including the projected chargers-rectifiers.
The busbar capacity for 24 VDC auxiliary service board (TD MC) wont be less
than 400 A, which shall be fed from its charger-rectifier. A 20x5 mm painted
copper bar is recommended.
There will be one (01) lead acid battery bank, with 12 cells that shall has 72
hours independent autonomy, and 100 Ah capacity.
The short-circuit capacity for 24 Vdc auxiliary service switches and busbars
shall be 14 kA.
12. ATTACHMENTS
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APPENDIX A
LIST OF ELECTRICAL CONSUMERS
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(*)
DIESEL GENERATOR
SELECTION
Final
Maximum Demand Select Power Design Power
DESCRIPTION Factor Selected
(kW) (kVA) (kVA)
Power (kVA)
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From the table shown; a 50x5 mm painted copper bar per phase is selected for auxiliary service in alternating current (TD
AC), because is the smallest bar size that can carry more than 630A
From the table shown; a 20x5 mm painted copper bar is selected for auxiliary service in direct current (TD DC), because is
the smallest bar size that can carry more than 200A
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APPENDIX D
CELL NUMBER CALCULATION FOR THE 24VDC BATTERY BANK
Definitions
* Flotation Voltage: voltage that ensures that the battery will remain charged.
* Equalization voltage: voltage needed to charge the battery. It is also known as load voltage.
* Deep charging voltage: voltage needed for the first charge and recommended in certain cases of
maintenance.
* Cycle: period of time specified to feed the expected load current.
* Period: time interval for each cycle of battery life.
* Capacity: the capacity required in Ah on plates; assigned to batteries banks or plates by cell, that
are fabricated for the discharge time.
Given the operating conditions for 24 VDC equipment, a tolerance limit is established for battery bank
voltage level. With new electronic and numerical solid state technologies; the equipment can support
up to 25% of the nominal operating voltage in the SS.AA bar, however a limit of 10% is established at
the lower limit, then the operating voltage range is 21.6 to 26.4 Volts.
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According to specifications, the battery discharge voltage should be 1.72 Vdc for each cell for
Lead-Acid type, which must be achieved within 8 hours
Number
of cells
= 12
Therefore, 12 cells are chosen, which will provide a minimum of 21,6 VDC, guaranteeing the
minimum required system voltage.
According to manufacturers' catalogs, the flotation voltage for Pb-Acid batteries is between 1,83 VDC
and 2,23 VDC.
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APPENDIX E
BATTERIES SELECTION
Charge Vdc : 24
Days of Autonomy : 3
Panel Charge
Star
Signal and Instrume- Communi- Panel
Power Relays Alarms
Controller ntation cation HMI
Switch
Total Demand (kW) 0.10 0.10 0.14 0.10 0.10 0.10 0.10
Coincided Factor 0.50 0.50 1.00 1.00 1.00 1.00 1.00
Maximum Demand (kW) 0.05 0.05 0.14 0.10 0.10 0.10 0.10
Current Maximum
2.08 2.08 5.83 4.17 4.17 4.17 4.17
Demand (A)
Equipment Qty
479 - 480 2.08 2.08 5.83 4.17 4.17 4.17 4.17 26.67 7.19 191.85
478 - 479 5.83 4.17 4.17 4.17 4.17 22.50 7.18 -29.92
477 - 478 5.83 4.17 4.17 4.17 4.17 22.50 7.17 0.00
476 - 477 5.83 4.17 4.17 4.17 4.17 22.50 7.15 0.00
475 - 476 5.83 4.17 4.17 4.17 4.17 22.50 7.14 0.00
474 - 475 5.83 4.17 4.17 4.17 4.17 22.50 7.13 0.00
473 - 474 5.83 4.17 4.17 4.17 4.17 22.50 7.11 0.00
472 - 473 5.83 4.17 4.17 4.17 4.17 22.50 7.10 0.00
471 - 472 5.83 4.17 4.17 4.17 4.17 22.50 7.09 0.00
470 - 471 2.08 5.83 4.17 4.17 4.17 4.17 24.58 7.07 14.74
239 - 240 2.08 5.83 4.17 4.17 4.17 4.17 24.58 3.95 0.00
238 - 239 5.83 4.17 4.17 4.17 4.17 22.50 3.94 -8.21
237 - 238 5.83 4.17 4.17 4.17 4.17 22.50 3.92 0.00
236 - 237 5.83 4.17 4.17 4.17 4.17 22.50 3.91 0.00
235 - 236 5.83 4.17 4.17 4.17 4.17 22.50 3.90 0.00
234 - 235 5.83 4.17 4.17 4.17 4.17 22.50 3.88 0.00
233 - 234 5.83 4.17 4.17 4.17 4.17 22.50 3.87 0.00
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Where:
n = 1/(Ft x Fe x Fd)) = 1.30
C = 160.00 AH
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APPENDIX G
SELECTING THE NOMINAL CURRENT OF THE 24V DC RECTIFIER
SWITCHBOARD TD MC
The nominal current of the rectifier will be sufficient to supply the maximum load plus
the current necessary for the recharge of the battery bank.
The required charge current of the battery bank capacity and the time required for
recharging, in addition to the battery charge factor (1.2 for lead-acid batteries).
For rectifiers with UI curves and voltage limits of 2.23 V / cell, the required nominal
current is calculated as follows:
C r Ch f
I n Lc
Tr
Where:
Rated current In (A)
Recharge time Tr (h)
Required capacity Cr (Ah)
Charging current Lc (A)
Battery charge factor Chf
Determinacin de la Carga Permanente en: 24 VDC
In the substation for the rectifier for the loads in 24 VDC you have:
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2.00 kW
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