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Operation and Analysis of Float Cum Boost Charger in High-Voltage

Switchgear Backup System

Conference Paper · November 2018

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 Operation and Analysis of Float Cum Boost Charger
in High-Voltage Switchgear Backup System
Fazel Mohammadi, Member, IEEE
Department of Electrical and Computer Engineering
University of Windsor
Windsor, ON N9B 1K3, Canada
email address: fazel@uwindsor.ca, fazel.mohammadi@ieee.org
Abstract—The main aim of this paper is to provide an
uninterruptible, stable and reliable power supply with the help of
battery charger and battery bank which can be used for the
operation of the switchgear and protection devices in the
substations. Each feeder in the power system has its own
protection devices that protect the power system from unwanted
faults. Therefore, which require uninterruptible DC auxiliary
supply to function. In order to operate these devices, the Float
Cum Boost Charger (FCBC) is analyzed which both converts the
AC power to the DC power to feed the auxiliary power supply
and also charges the battery bank to store the energy and inject it
into the system when it needed. It provides 100% no-break
supply to the critical loads. The main parameters to be
considered are, the capacity of the battery bank, the type of
battery, supplying enough power to operate the protection
devices, the charging time of all the batteries, etc.
Keywords—Battery Bank, Backup System, Float Cum Boost
Charger (FCBC), Protection Devices, High-Voltage Switchgear.
I. INTRODUCTION
Power supply units are the most important part of the
electrical generation and distribution systems especially in the
case of substations. To mitigate the problem of power
instability, such kind of Float Cum Boost Charger (FCBC) also
known as Uninterrupted Power Supply (UPS) system is more
often used in substations. Considering the reliability and
efficiency as the important factors, the DC supply is more
favorable than AC supply [1]. The source of DC can be either
in the form of the battery bank or it can be rectified from AC to
DC. Less noisy and fast reacting DC supply is required by
these types of components. FCBC has the same application as
UPS which converts the AC power into the DC power and
charges the battery. In addition, it provides stable auxiliary
supply to the electrical equipment whether the main supply is
available or not. During the failure of the main supply, the
battery bank will supply the power for a limited time duration
that will be depending upon the size of the battery bank and
load [2]. That is why FCBCs with battery banks are mandatory
in each substation.
In FCBC there are two types of operating mode: (1) Float
mode, and (2) Boost mode. In float mode, the regular supply is
given to the load and the battery is charged at low voltage. This
mode is generally used when the battery is in a good state and
less discharging condition [3-4]. For most of the time, the
FCBC will operate in this mode. In case of boost mode, the
supply to the load will remain the same, but the charging speed
of battery will be increased with the help of high current for
short duration of time and this will be occurring when the
battery is getting more discharged or in case of limited time
duration of normal supply [3-5].
Depending on the state of the battery which is determined
by the sensors, the FCBC will decide in which it will be
operating. If the battery gets discharged linearly, then FCBC
will trigger the float mode that will raise the charging voltage
to charge the battery [3-4]. However, if the battery gets
discharged gradually, then the FCBC will trigger the boost
mode to charge the battery instantly which triggers higher
voltage than Float mode. These modes can be selected either
manually or automatically for which the selector switches and
electrical schemes are incorporated [2-5].
This paper mainly focuses on the operation and analysis of
the Float Cum Boost Charger (FCBC) as an important unit in
substations which can provide uninterruptable, stable and
reliable power supply to protect and control the devices in
switchgear panels and keep the system fault free and healthy.
Moreover, in order to provide practical results, the battery unit
sizing and the battery charger sizing under different charging
modes based on IEEE Standard 485-1997 have been
calculated.
This rest of paper is organized as follows. Section II
provides the operation principles of the Float Cum Boost
Charger. Analysis of the Float Cum Boost Charger is discussed
in Section III. Sections IV and V investigate the calculations of
battery sizing as per IEEE Standard 485-1997 and battery
charger sizing for float/boost charging modes, respectively.
Lastly, Section VI indicates the conclusions.
II. OPERATION PRINCIPLES OF FLOAT CUM BOOST CHARGER
When the main AC supply is available, the float rectifier
will convert the supply from AC to DC and fed it to the load.
In addition, it will also charge the battery bank by supplying
constant low voltage. When the float rectifier switch is
energized and is in ON condition, the FCBC will operate on
Float mode during which it will provide supply to the load and
having the DC switch energized and is in ON condition, the
battery bank will charge through float rectifier. When the main
AC supply is not available, the load will get the supply from
the battery bank without any interruption as a backup supply
which provides the constant voltage. When the power supply
resumes, the supply from the battery bank will cut-off and the
float rectifier will supply power to the load as well as charge
the drain battery unit. In case of heavy discharge of the battery
bank and the availability of the main supply, the FCBC will
select Boost mode to charge the battery bank instantly. Under
this condition, the float rectifier will inject high current to the
battery bank to recharge it in a short duration, subsequently.
Float rectifier will continue to provide power supply to the
load. Under the service condition of float rectifier or during the
failure of float rectifier, the main power supply gets switched to
the Boost mode and boost charger will feed the load as well as
the battery unit which is also considered as a backup of float
charger. This configuration will act as a more reliable and Fig. 1: The Block diagram of FCBC unit
uninterruptible power supply to the load as well as the battery
bank when the float rectifier is not under working condition There will be unstable DC output due to variation in line
[4]. voltage and load current which is controlled by the gate firing
angle of the thyristor. To control and generate these firing
III. ANALYSIS OF FLOAT CUM BOOST CHARGER pulses of the thyristor main controller and firing card (CC/CV
The FCBC generally monitors through a full wave rectifier control card) is used. The samples of the input voltage, for
which also works on phase angle control theory. The main stabilizing the output voltage with respect to the input voltage,
function of the FCBC is to charge the battery in float mode, is taken through the synchronous transformer. These
when some small internal losses are existing and in the boost transformers generate the pulses which are mounted on the
mode after it gets discharged. Also, it supplies power to the main control card. The output voltage is stabilized against the
load during the mains failure maintaining the voltage across specific variation of line voltage up to the rated output voltage
the load terminals. which is controlled by the main control card. Limits of the
According to the given schematic in figure 1 [5], the input current are set by the main control current where output
supply is of 415 A with ±10% tolerance, 3-phase 50 Hz is current start dropping if the load goes below the set value of
terminated across input terminals. MCCB-1 is provided to current.
connect and disconnect the main supply. The existence of The initialization relay should be provided in the main
current and voltage will be measured through AC voltmeter control card which is used for soft start building up the output
which reads the line voltage and the AC ammeter that measures voltage. Control card needs the battery current set
line current with the help of the current transformer. FCBC potentiometer which sets the maximum charging current limit
needs the contactor which works as a safety interlock during that can be drawn by the battery bank. Also, an auto-manual
the failure of input supply or any fault occurred in the charger.
selector switch required which in auto mode, firing pulses of
During this process, the contactor will get energized, trip the
circuit and bypass the system to protect the electrical the thyristor can be adjusted automatically through the
equipment. TX1 is the main transformer which is used to step- controller. While in manual mode, the firing angle is adjusted
down the input voltage supply. This step-down AC is rectified manually with the help of the manual potentiometer.
by M1 to M3 thyristor module which is protected by the From the other side, a charging mode selector switch is
control circuit fuses F1-F6. This converted DC supply is needed. For this selection mode, mode selector relay is also
filtered using the filter. The output DC is terminated across the used which energizes the selector switch. The charging can be
terminal used for battery bank and load. done in the following ways: (1) If the charging mode selector
switch is kept at float position, batteries may charge at 2.25
V/cell. The potentiometer sets this voltage, (2) If the charging
mode selector switch is kept at boost position, voltage is set at
2.3 V/cell, and charges at constant voltage, this value is set by
the potentiometer, and (3) If the charging mode selector
switch is kept at auto position, the battery will charge iv. Spring charged
automatically in different modes. In each mode, the voltage v. Test service position
setting can be done during the installation or voltage in each vi. Semaphore indicators for the circuit breaker, isolator,
mode will be factory set. This voltage rating must not be and earth switch position
changed after installation.
Control card is also known as the Annunciation Circuit Table 2. Summary of the number of indicating lamps for 11 kV
which indicates the fault. Different cards have different fault SWGR and 132 kV CRP
sensing applications which give input to the annunciation card
SWGR Feeder Type No. of No. of Total
and as an output of its annunciator will indicate the fault. To Feeders Lamps Qty.
isolate the fault voltage and control voltage fault, the 11 kV SWGR1 Incomer 1 5 5
electronic circuit optocouplers are used in fault sensing cards. Outgoing 5 5 25
Optocouplers turn on when it senses the fault voltage and Aux. 1 5 5
Transformer
gives status input to annunciator. The LED indicating card can 11 kV SWGR2 Incomer 1 5 5
give an indication when the fault in the charger has occurred. Outgoing 5 5 25
When the fault occurs, along with LED, the alarm also turns Aux. 1 5 5
on and this audio will be stopped by using the push button. Transformer
132 kV CRP 132 kV Trans. 2 5 10
There is a relay provided on the card which energizes the fault Bay
trip contactor as discussed earlier. There are also potential free 132 kV Line. 1 5 5
contacts available which give provision for remote alarm for Bay
charger failure. Total No. of 85
Lamps

IV. BATTERY SIZING AS PER IEEE STANDARD 485-1997

Total load of indicating lamps
A. Battery and Battery Charger System for Switchgear Control = 255.00 W (1)
Table 1 shows the specification of FCBC. The calculations
have been performed using the IEEE Standard 485-1977 [6-7]. Total semaphore indicators for earth switch position
indication is 12. Therefore, the total load of semaphore
Table 1. The specification of FCBC indications
= 30.00 W (2)
Parameter Description
Input Voltage 415V ± 15%
Input Frequency 60Hz ± 10% Table 3. 11 kV incomer and outgoing feeder
Nominal Output voltage 110V DC
Protections Relay Qty. Unit Total
Maximum Voltage 121V DC
Watt Watt
Minimum Voltage 99V
Individual Cell Voltage 2V DC Feeder Protection Relay MICOM 1 3.25 3.25
Battery End Cell Voltage 1.75V DC P111
Battery Type VRLA Trip Circuit Supervision VAX31 2 1.56 3.12
Battery Backup Time 3 Hours (180 Min) Relay
Ambient Temperature 45° C Annunciator Windows ANNUN 1 7.5 7.5
Aging Factor 25%
Design Margin 13%
B. Protective Relays in Relay Panel and Switchgears

Table 4. 11 kV aux. transformer

The duty cycle of the battery is based on the following DC
loads: Protections Relay Qty. Unit Total
Watt Watt
Feeder Protection Relay MICOM 1 3.25 3.25
A Continuous Load and Indicating Lamps (CRP, 11 kV P111
SWGR 1 And 2 in the Control Room): Trip Circuit Supervision VAX31 2 1.56 3.12
Relay
In the worst-case scenario, indicating lamps and/or Aux. Relay VAA33 2 1.56 3.12
Annunciator Windows ANNUN 1 7.5 7.5
semaphore shall remain ON/OFF at a time for the following
types of feeders’ breaker:

i. Breaker ‘Open/Close’
ii. Breaker ‘Auto-Trip’
iii. Trip circuit healthy
 Table 5. 132 kV transformer bay A Typical fault is considered on 132 kV bus leading to
Protections Relay Qty. Unit Total tripping of one 132 kV O/G SF6, Transformer Bay and 11 kV
Watt Watt VCB breakers for battery sizing.
Numerical O/C and E/F P127 1 3.25 3.25
Protection Table 7. Supplying momentary loads during the first minute (tripping
Differential Protection P642 1 12.6 12.6
operation) by the battery
Trip Circuit Supervision Relay VAX31 2 1.56 3.12
Supervision Relay VAA11 1 1.56 1.56 SWGR Feeder type No. Watts per Total
Aux. Relay VAA33 4 1.56 6.24 FDR Watt
Annunciator Windows ANNUN 1 7.5 7.5 132 kV Transformer Transformer 1 690 690
Bay Bay
Table 6. 132 kV line bay 132 kV O/G Bay O/G Bay 1 692 690
11 kV SWGR-1 I/C 1 150 150
Protections Relay Qty. Unit Total 11 kV SWGR-2 I/C 1 150 150
Watt Watt Hooter - - 100 150
Numerical O/C and E/F P127 1 3.25 3.25 Total Load During the First Minute 1780
Protection
Distance Protection P442 1 18 18
Trip Circuit Supervision Relay VAX31 2 1.56 3.12
Hence, the load in Amp. = 1780 W÷110 V
Supervision Relay VAA11 1 1.56 1.56 ~ 17.00 A (10)
Annunciator Windows ANNUN 1 7.5 7.5
Aux. Relay per Feeder and Burden of 150 W per Aux.
For 11 kV Switchboard: Relay:

Total load of the protection relay, Load of Aux. Relay

= 13.87×10 (as 10 No. of incomer feeders) = 4×150 W / Aux relay (2× 132 kV and 2×11 kV)
= 13.87×2 (as 2 No. of outgoing feeders) = 5.45 A [or ~6.00 A] (11)
= 16.99×2 (as 2 No. aux. transformers)
= 200.42 W (3) Additional continuous load
= 15.00 A (12)
For 132 kV Transformer 1 and 2 Control and Relay Panel:
The summation of (10), (11), and (12) gives the total load
Total load of the protection relay current at the beginning of the battery load cycle which is
= 68.54 W (4) equal to 38.00 A.

For 132 kV Line 1 Control and Relay Panel: 2) Last Minute Load At the End of 179 min (179 to 180 min)

Total load of the protection relay Table 8. Supplying momentary loads during the last minute before
= 33.43 W (5) the AC supply is available to the battery charger (closing operation)
by the battery
Total load of the protection relay = (3) + (4) + (5) SWGR Feeder type No. Watts per Total
= 302.39 W [or ~303.00 W] (6) FDR Watt
132 kV Transformer Transformer 1 345 345
Bay Bay
Future/other loads: 132 kV O/G Bay O/G Bay 1 345 345
= 1000.00 W (7) 11 kV SWGR-1 I/C 1 150 150
11 kV SWGR-2 I/C 1 150 150
Total Load During the Last Minute 990
Total continuous load = (1) + (2) + (6) + (7)
= 1587.39 [or ~ 1588.00 W] (8) Hence, load in Amp. = 990 W÷110 V
~ 9.00 A (13)
Hence, load in Amp. = 1588 W÷110 V
~ 15.00 A (9) Adding continuous load
= 15.00 A (14)
1) First Minute Load at Beginning of the Battery Load Cycle
(0 to 1 min) The total continuous load is the summation of (13) and
(14) which is equal to 24.00 A.
C. Numerical Calculations Battery charger rating considered the float charging
In order to calculate the number of cells, normal cell requirement is 110 V, 20 V.
voltage (2 V) and minimum cell voltage (1.75 V) are required.
The number of required cells can be derived from dividing the B. Battery Charger Sizing for Boost Charging
minimum battery voltage by minimum cell voltage. Boost charging current= (1.25×Ah of the battery) ÷ 10
Consequently, the number of required cells is 57. Hence, a
battery bank consists of 57 cells of 2 V per cell is selected. Therefore, the selected battery size in Ah is equal to 100
Ah. Hence, the boost charging current,
Table 9. Load summary = (1.25×100) ÷ 10
Period Loads Loads in = 12.50 A (17)
Amp.
Section I Momentary Tripping Load + Continuous 38.00 Battery charger current rating,
Load = 13.00 A (18)
Section II Continuous Load 15.00
Section III Momentary Closing Load + Continuous 24.00
Load Battery charger rating considered the boost charging
requirement is 110 V, 13 A. Hence, based on the practical
Table 10. Load duration and capacity existing range for the current, the battery charger rating is
Period Load in Amp. Duration (min) Capacity Removed (Ah)
110 V, 20 A.
Section I 38.00 1.00 0.64
Section II 15.00 178.00 44.5 VI. CONCLUSIONS
Section III 24.00 1.00 0.4
Total 45.54 The battery banks can be considered as the perfect source to
provide uninterruptible power supply to all electrical
equipment. There is a compulsion to use battery charger along
Maximum Ah capacity required is 64.03 Ah. Applying
with battery bank in a substation where it is necessary for all
various factors, such as aging factor (as 25%), design margin
protection and control devices in switchgear panels to work
(as 15%), and temperature derating factor (as 1), the required under stable and reliable power supply to protect the power
Ah is calculated as 93.0 Ah. Accordingly, 100 Ah is selected generation as well as distribution system and equipment. To
as the battery size. achieve these, the dependency on AC power supply which is
considered as the unstable source will be inadequate. The
V. BATTERY CHARGER SIZING CALCULATION FOR battery charger can convert AC into stable DC supply which
FLOAT/BOOST CHARGING feeds load and battery units together. Nowadays, neither
Based on the aforementioned descriptions and calculations, commercial sectors nor civilians could afford power cut-off as
the recommended battery size is 100 Ah and the DC nominal it costs a lot in different manners. Therefore, Float Cum Boost
voltage is 110 V (as per standard practice) [8-9]. Charger (FCBC) plays an important role in substations by
providing uninterruptable, stable and reliable power supply to
protection and control devices in switchgear panels that keep
A. Battery Charger Sizing for Float Charging the system fault free and healthy.
Battery charger current rating is the sum of the continuous
load current and the float charging current of the battery. The REFERENCES
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