CEDAR 33kV BESS

ARC FLASH ANALYSIS STUDY

Date: 12/03/2024

Reference: 00981- 07809 – CRXX

Revision: 00

Prepared By: Danish Uddin

Reviewed By: Mohammad Abdullah

Approved By: Adeel Khan

Prepared For:

ESM Power Limited

Woodford House
44 North Farm Road
Scunthorpe
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TABLE OF CONTENTS
LIST OF TABLE...........................................................................................................................................4

ABBREVIATIONS.......................................................................................................................................5

EXECUTIVE SUMMARY..............................................................................................................................7

1. REVISION HISTORY................................................................................................................................8

2. INTRODUCTION....................................................................................................................................8
2.1. PURPOSE / SCOPE.................................................................................................................................8
2.2. STANDARDS...........................................................................................................................................8

3. STUDY DATA.........................................................................................................................................9

4. ARC FLASH HAZARD ANALYSIS (AS PER NFPA 70E-2021)......................................................................10

4.1. INCIDENT ENERGY:..............................................................................................................................10
4.2 ARC FLASH BOUNDARY:.......................................................................................................................11
4.3 ARC FLASH INCIDENT ENERGY METHOD:.............................................................................................11

5. METHODOLOGY..................................................................................................................................12
5.1 ARC FLASH ANALYSIS USING RELAY TCC TRIPPING...............................................................................12
5.2 ARC FLASH ANALYSIS USING FIXED CLEARING TIME.............................................................................13

6. ARC FLASH ANALYSIS - RESULTS..........................................................................................................14

6.1 ARC FLASH ANAYLYSIS USING RELAY TRIPPING:...................................................................................14
6.2 ARC FLASH ANAYLYSIS USING FIXED CLEARING TIME...........................................................................14

ADD A LABELLING TAG, WRITE ABOUT IT AND ATTACH A SNAPSHOT AS DISCUSSED IN OUR CALL...........15
6.3 ARC FLASH LABELS................................................................................................................................15

7. CONCLUSION:.....................................................................................................................................15

7. REFERENCES........................................................................................................................................16

APPENDIX A............................................................................................................................................17

APPENDIX B............................................................................................................................................20

APPENDIX C............................................................................................................................................23

APPENDIX D............................................................................................................................................26

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LIST OF TABLE
Table 1: Equipment details of Arc Flash Panels................................................................................................7
Table 2: Arc Flash PPE Categories for AC system [1]........................................................................................8
Table 3: Arc Flash PPE Catagory as per NFPA 70E-2021...................................................................................9
Table 4: Arc Flash Analysis with Relay Tripping..............................................................................................10
Table 5: Arc Flash Analysis with Fixed Clearing Time......................................................................................11

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ABBREVIATIONS

VCB Vacuum Circuit Breaker

Al Aluminium
GIS Gas Insulated Switchgear
CB Circuit Breaker
CSA Cross Sectional Area
CT Current Transformer
Cu Copper
DT Definite Time Curve
E/F Earth Fault
FLA Full Load Amps
GPS Generator Performance Standard
HV High Voltage
IED Intelligent Electronic Device
I> Low Set Overcurrent
I>> High Set Overcurrent
IE> Low Set Earth Fault
IE>> High Set Earth Fault
Id Differential Current
Idiff Differential Current
Ibias Bias Current
LV Low Voltage
O/C Over Current
PF Power Factor
PoC Point of Connection
POC Pick-up Current
PCS Power Converter System
PMS Plug Multiplier Setting
RMU Ring Main Units
SI Standard Inverse (IEC Curve type)
TMS Time Multiplier Setting

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Vk Knee Point Voltage

XLPE Cross-linked Polyethylene
PPE Personal Protective Equipments
J Jules
Units
A Amperes
kA KiloAmps
kV Kilovolt
MVA Megavolt-Amperes
MW Megawatt
p.u. Per Unit

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EXECUTIVE SUMMARY

This report presents the Arc Flash hazard analysis study conducted for the CEDAR COTTAGE Battery Energy
Storage System (BESS) Project, focusing on the 33kV system. The Arc Flash studies were conducted using
PowerFactory DIgSILENT®, developed by DIgSILENT® GmbH, Germany. DIgSILENT® GmbH is an established
company specializing in power system software and consulting services.

The Arc Flash hazard study, performed according to NFPA 70E-2021 [1] and Ralph Lee Method. The
calculations were performed for 33kV switchgear, 0.69kV BESS transformer main LV Panels and 0.4kV Aux
Transformer main LV panel. This is noted that NFPA 70E-2021 is not applicable for above 15kV 1 switchgears
[1]. The customer substation operates at 33 kV, which is generally considered outside the scope of NFPA
70E. However, it is common practice in the industry to use the Ralph Lee Method for calculating the arc-
flash incident energy when the voltage is above 15 kV. Therefore, for the 33 kV equipment, we'll be using
the Ralph Lee Method for arc-flash analysis. On the other hand, for the LV equipment, we'll be using the
NFPA Incident Energy Analysis method.

The selection of PPE category and arc flash labels according to the incident energy levels are provided in
this report.

1
Please refer page no. 60 of NFPA 70E-2021 [1]

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1. REVISION HISTORY
Date Revision Comment
22/02/2023 0 Issued For Review

2. INTRODUCTION
The CEDAR-Basildon substation is a 33kV Battery Energy Storage System (BESS) substation with a maximum
capacity of 28MW for import and export. This facility will be linked from the 33kV UK Power Networks
(UKPN) Grid substation to the Point of Connection (POC), namely the Basildon 33kV Grid substation, with
the connection established through the 33kV UKPN. The Basildon BESS site, situated north of Basildon
Substation on Lower Dunton Road, Horndon on the Hill, Basildon (RM14 3TD) is located near a stream
along its southern border and relative to the sea. The system boasts a power capacity of 28 MW AC
measured at the POC and an energy capacity of 56 MWh.

The site comprises of an incoming feeder and 5 outgoing feeders. The incoming feeder will be connected
from the 33kV DNO Switch room. However, out of 5 outgoing feeders, four feeders are dedicated to the
8.78 MVA BESS transformer, and one feeder will be connected to the Auxiliary Transformer for running the
Auxiliary supplies. The single-line diagram of the site is attached Appendix B.

2.1. PURPOSE / SCOPE

This report aims to provides a comprehensive analysis of Arc Flash hazards, including the measurement of
incident energy levels, the determination of arc flash boundaries across a plants’ switchgears and based on
incident energy levels suggest personal protective equipment (PPEs). The calculations were performed for
0.69kV BESS transformer main LV Panels and 0.4kV Aux Transformer main LV panel. However, we have also
performed arc flash hazard study for 33kV DNO switch room and 33kV customer switch room using NFPA
70E-2021 standard. This is noted that NFPA 70E-2021 is not applicable for above 15kV 2 switchgears [1] and
currently no other standards are available for above 15kV.

2.2. STANDARDS
The Arc Flash hazard analysis is performed as per the NFPA 70E-2021 [1] at the CEDAR BESS plant that are
sufficient to meet the requirements as stated [1]. Additionally, the report guides the selection of Personal
Protective Equipment (PPE) in accordance with NFPA 70E standards.

2
Please refer page no. 61 of NFPA 70E-2021 [1] .

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3. STUDY DATA
This section provides equipment-specific data used in the study to calculate the Arc Flash levels at CEDAR
BESS plant. CEDAR BESS plant comprises a different voltage level, i.e. 33kV, 0.69KV and 0.4KV. A summary
of possibly arc flash equipment shown below with switchgear and panel details Table 1.

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Table 1: Equipment details of Arc Flash PanelsPlease add panel

EQUIPEMENT WIDTH HEIGHT DEPTH

33kV DNO Switchroom Panels [2] 600 mm 2425 mm 1364 mm
33kV Customer Switchroom Panels [3] 600 mm 2615 mm 1364 mm
0.69kV BESS Transformer Main LV Panels[4] 800 mm 2300 mm 600 mm
0.4kV AUX Transformer Main LV Panel [4] 800 mm 2300 mm 600 mm

Details for customer swichroom layout which includes the dimensions and drawings of Switchgears and
main LV Panels have been provided in Appendix C.

4. ARC FLASH HAZARD ANALYSIS (AS PER NFPA 70E-2021)

Arc Flash Hazard Analysis is a crucial part of ensuring safety in the workplace where electrical equipment is
involved. It is required by OSHA’s and is further detailed in the NFPA 70E Standard for Electrical Safety in
The Workplace [1].

The goal of an Arc Flash Hazard Analysis, according to NFPA 70E [1], is to identify:
 The Flash Protection Boundary, defined as an approach limit at a distance from exposed live parts
within which a person could receive a second-degree burn if an electrical arc flash were to occur.
 The proper personal protective equipment (PPE) and protective clothing necessary, based on an
incident heat energy calculation for the working distance for the task to be performed.

An Arc Flash Study considers short-circuit current and time of operation of protective device to calculate
the arc flash intensity on each equipment.

4.1. INCIDENT ENERGY:

Incident energy, also known as Arc Flash Energy, is a measure used to assess the severity of an arc flash. It's
quantified in Joules per square centimetres (J/cm2). The higher the incident energy, the more severe the
arc flash and resulting burn injuries. The incident energy is also directly affected by the duration of the arc
and the available bolted fault current. Essentially, the longer the arc flash persists and the higher the fault
current, the greater the incident energy. Engineering analysis is crucial to determine how quickly protective
equipment can operate and isolate a short-circuit. Longer operation times result in higher incident energy
levels.
As per the NFPA 70E, Incident energy can be calculated using the below equation [1]

6
E=2.142× 10 V I bf
( Dt )
2

J
E = incident energy 2
cm
Ibf= Bolted fault short circuit current, KA.

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V = System Phase to Phase voltage, KV.

t = Arc duration, sec.
D = distance (mm) from the arc to the person (working distance)

4.2 ARC FLASH BOUNDARY:

The arc flash boundary (also known as the restricted approach boundary) represents the minimum safe
distance from exposed energized conductors or circuit parts where an unqualified worker can approach
without wearing Personal Protective Equipment (PPE). At this distance, a worker without appropriate PPE
would be at risk of second-degree burns in the event of an arc flash incident.

4.3 ARC FLASH INCIDENT ENERGY METHOD:

When using the Incident Energy Analysis Method, Personal Protective Equipment (PPE) is divided into two
levels based on the level of exposure to incident energy. The first level is for incident energy exposures
ranging from 1.2 cal/cm2 up to 12 cal/cm2, while the second level is for incident energy exposures greater
than 12 cal/cm2. There are no categories, and the arc rating specified on the PPE must be higher than the
calculated energy, which should be indicated on the label. The PPE requirements are shown in Table 2.

Table 2: Arc Flash Incident Energy Analysis Method as per NFPA 70E-2021 Table 130.5(G)

Incident Energy Exposure Details

Arc-rated clothing with an arc rating equal to or greater than the
estimated incident energy
Arc-rated long-sleeve shirt and pants or arc-rated coverall or arc flash
suit (SR)
Arc-rated face shield and arc-rated balaclava or arc flash suit hood (SR)b
Arc-rated outerwear (e.g., jacket, parka, rainwear, hard hat liner, high-
Equal to 1.2 cal/cm2 up to and
visibility apparel) (AN)e
including 12 cal/cm2
Heavy-duty leather gloves, arc-rated gloves, or rubber insulating gloves
with leather protectors (SR)c
Hard hat
Safety glasses or safety goggles (SR)
Hearing protection
Leather footwear
greater than 12 cal/cm2 Arc-rated clothing with an arc rating equal to or greater than the
estimated incident energy
Arc-rated long-sleeve shirt and pants or arc-rated coverall or arc flash
suit (SR)
Arc-rated arc flash suit hood
Arc-rated outerwear (e.g., jacket, parka, rainwear, hard hat liner, high-
visibility apparel) (AN)e
Arc-rated gloves or rubber insulating gloves with leather protectors
(SR)c
Hard hat
Safety glasses or safety goggles (SR)

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Hearing protection
Leather footwear
Where:
SR: Selection of one in group is required.
AN: As needed.
a-Arc ratings can be for a single layer, such as an arc-rated shirt and pants or a coverall, or for an arc flash
suit or a multi-layer system if tested as a combination consisting of an arc-rated shirt and pants, coverall,
and arc flash suit.
b-Face shields with a wrap-around guarding to protect the face, chin, forehead, ears, and neck area are
required by 130.7(C)(10)(c). Where the back of the head is inside the arc flash boundary, a balaclava or an
arc flash hood shall be required for full head and neck protection.
c-Rubber insulating gloves with leather protectors provide arc flash protection in addition to shock
protection. Higher class rubber insulating gloves with leather protectors, due to their increased material
thickness, provide increased arc flash protection.
d-Footwear other than leather or dielectric shall be permitted to be used provided it has been tested to
demonstrate no ignition, melting, or dripping at the estimated incident energy exposure.
e-The arc rating of outer layers worn over arc-rated clothing as protection from the elements or for other
safety purposes, and that are not used as part of a layered system, shall not be required to be equal to or
greater than the estimated incident energy exposure

5. METHODOLOGY
Arc flash hazard analysis is conducted using the DiGSILENT PowerFactory v22.0 software. This software
utilizes calculations compliant with NFPA 70E for arc flash assessments. The three-phase arcing current is
computed, and the three-phase bolted fault current is established through short circuit studies.
Additionally, the duration of the arc flash is determined by analysing the Time-Current Characteristic (TCC)
curves of protective devices alongside the calculated arcing fault current.

We have considered two cases for the Arc flash hazard analysis.
1. Arc Flash Analysis using relay TCC tripping.
2. Arc Flash Analysis using fixed time.

5.1 ARC FLASH ANALYSIS USING RELAY TCC TRIPPING

Arc flash analysis using relay Time Current Characteristic (TCC) tripping involves understanding the behavior
of overcurrent protective devices in response to fault conditions. The duration of an arc flash, which is
crucial for determining the incident energy (a key factor in arc flash analysis), is typically defined by how
long it takes an upstream overcurrent device to operate and clear the fault. Results will be discussed in the
section 6.

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5.2 ARC FLASH ANALYSIS USING FIXED CLEARING TIME

Arc flash analysis using fixed clearing time were performed as a worst-case scenario. If the dedicated
protective relay is unable to clear the fault due to malfunctioning, upstream relay will initiate the command
to clear the fault. In this case we have considered the upstream relay setting as a fixed clearing time.
Results will be discussed in the section 6.

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6. ARC FLASH ANALYSIS - RESULTS

Arc flash analysis were performed as per the NFPA 70E-2021. We have examined two scenarios for the Arc
flash hazard analysis.
1. Arc Flash Analysis using relay TCC tripping.
2. Arc Flash Analysis using fixed time.

6.1 ARC FLASH ANAYLYSIS USING RELAY TRIPPING:

Following results were obtained while performing the arc flash study using relay tripping, shown in Table 3.

Table 3: Arc Flash Analysis with Relay Tripping

Arcing
Voltag Arc Flash Incident Incident
Equipment Rela Current
e Duration Boundar Energy Energy
name y (kAmps
(kV) (Sec) y (mm) (J/cm2) (Cal/cm2)
)
ABB
UKPN ONSITE
REX 33 12.96 0.1 4278 110.52 26.41
SWITCH ROOM
640
33KV ABB
CUSTOMER REF 33 12.93 0.1 4274 110.28 26.35
SWITCHROOM 620
BESS Trafo LV
- 0.69 51.65 0.05 873 10.25 2.51
Panel
AUX Trafo LV
- 0.4 33.63 0.02 339 3.910 0.934
Panel

6.2 ARC FLASH ANAYLYSIS USING FIXED CLEARING TIME

Following results were obtained while performing the arc flash study using fixed fault clearing time i.e 0.1
sec, as shown in .

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Table 4: Arc Flash Analysis with Fixed Clearing Time.

Bolted
Arcing Arc Incident Flash
Voltage Fault PPE
Equipment name Relay Current Duration Energy Boundary
(kV) Current Catagory
(kAmps) (Sec) (J/cm2) (mm)
(kAmps)
ABB
UKPN ONSITE
REX 33 12.96 12.96 0.1 110.52 4278 4
SWITCH ROOM
640
ABB
33KV CUSTOMER
REF 33 12.93 12.93 0.1 110.28 4274 4
SWITCHROOM
620
BESS Trafo LV
- 0.69 51.65 51.65 0.1 20.50 1235 2
Panel
AUX Trafo LV
- 0.4 33.63 33.63 0.1 19.55 757 2
Panel

Add a labelling tag, write about it and attach a snapshot as discussed in our call.
6.3 ARC FLASH LABELS
Arc flash labels provide the incident energy, arc flash boundary and working distance for each electrical
equipment in the system. They are attached directly onto the equipment on site. By prominently displaying
the information, arc flash labels allow maintenance workers to take necessary precautions by wearing
appropriate PPE while conducting repairs or servicing electrical equipment hence minimizing the risk of
accidents and injuries. Arc Flash Labels are attached in APPENDIX D.

7. CONCLUSION:
FEC Ltd. has conducted a comprehensive Arc Flash study for the CEDAR BESS plant that boasts a maximum
import and export capacity of 28MVA. The arc flash analysis study conducted as per the NFPA 70E standard
has provided valuable insights into the potential electrical hazards in our facility.

The study has identified areas of high risk and has recommended appropriate equipment for workers based
on the calculated incident energy levels. Some recommendation can be adopted such as:

1. Arc Flash Detection Relays can be installed.

2. Faster fault clearance time but be mindful of compromising the time grading of protection relays.
3. Increasing the working distance may reduce the incident energy.

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7. REFERENCES
[1] NFPA 70E - Standard for Electrical Safety in the Workplace – 2021 Edition. Available at:
https://edufire.ir/storage/Library/elam/NFPA%2070E-2021.pdf

[2] GENERAL ARRANGEMENT OF CEDAR BESS GENERATION CPG.0 Rev A SWITCHBOARD - 001-9-2241 PROV
A-ORMAZABAl.
[3] Customer Switch Room Layout - 00981-07809-E31 - ESM Power Limited
[4] GENERAL ARRANGEMENT DRAWING FOR LVAC SWITHGEAR PANEL – 00981-07809-E35 - ESM Power
Limited

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APPENDIX A
REFERENCE DATA

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Figure A- 1: Single Line Diagram

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APPENDIX B
PROTECTION
COORDINATION SETTINGS

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Table B- 1: 33kV Switchgear Bay Incomer (REX 640)

PROTECTION
PARAMETERS VALUE UNIT
FUNCTION

Status Enable - -
Function IEC S. Inverse 616 Amp (Primary)
51
Time Dial TMS 0.1 -
Directional Non- directional - -
Status Enable - -
Function Definite Time 1080 Amp (Primary)
50
33kV Incomer

ABB REX 640

Time Dial - 100 msec

SWG Bay

Directional Non- directional - -

Status Enable - -
Function IEC S. Inverse 104 Amp (Primary)
51N
Time Dial TMS 0.125 -
Directional Non- directional - -
Status Enable - -
Function Definite Time 296 Amp (Primary)
50N
Time Dial - 100 msec
Directional Non- directional - -

Table B- 2: 33kV Switchgear Bay BESS Transformer (REF 620)

PROTECTION
PARAMETERS VALUE UNIT
FUNCTION

Status Enable - -
Function IEC S. Inverse 192 Amp (Primary)
51
Time Dial TMS 0.075 -
Directional Non- directional - -
33kV BESS Transformers

Status Enable - -
ABB REF 620

Function Definite Time 340 Amp (Primary)

50
Time Dial - 50 msec
Directional Non- directional - -
Status Enable - -
Function IEC S. Inverse 32 Amp (Primary)
51N
Time Dial TMS 0.1 -
Directional Non- directional - -
50N Status Enable - -
Function Definite Time 94 Amp (Primary)

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Time Dial - 50 msec

Directional Non- directional - -

Table B- 3: 33kV Switchgear Bay AUX Transformer (REF 620)

PROTECTION
PARAMETERS VALUE UNIT
FUNCTION

Status Enable - -
Function IEC S. Inverse 22 Amp (Primary)
51
Time Dial TMS 0.05 -
Directional Non- directional - -
Status Enable - -
33kV AUX Transformers

Function Definite Time 40 Amp (Primary)

50
ABB REF 620

Time Dial - 20 msec

Directional Non- directional - -
Status Enable - -
Function IEC S. Inverse 16 Amp (Primary)
51N
Time Dial TMS 0.05 -
Directional Non- directional - -
Status Enable - -
Function Definite Time 16 Amp (Primary)
50N
Time Dial - 20 msec
Directional Non- directional - -

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APPENDIX C
CUSTOMER SWITCHROOM
DRAWING AND LAYOUT

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Figure 1: Switchgear Panel Drawing

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Figure 2: Customer Switchroom Layout

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APPENDIX D
ARC FLASH LABELS

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