eds 03-0300 battery and charger specification for grid...

Document Number: EDS 03-0300

Version: 4.1

Date: 03/09/2014

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ENGINEERING DESIGN STANDARD

EDS 03-0300

BATTERY AND CHARGER SPECIFICATION FOR GRID, PRIMARY AND EHV CUSTOMERS SUBSTATIONS

Network(s): EPN, LPN, SPN

Summary: This standard details UK Power Networks' requirements for the provision of new and replacement battery chargers incorporating Black Start Controller functionality.

Owner: Kevin Burt Date: 03/09/2014

Approved By: Steve Mockford Approved Date: 25/09/2014

This document forms part of the Company’s Integrated Business System and its requirements are mandatory throughout UK Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset Management. If you have any queries about this document please contact the author or owner of the current issue.

Circulation

UK Power Networks External

All UK Power Networks G81 Website

Asset Management Contractors

Capital Programme ICPs/IDNOs

Connections Meter Operators

HSS&TT

Network Operations

UK Power Networks Services

Other

Battery and Charger Specification for Grid, Primary and EHV Customers Substations


Version: 4.1

Date: 03/09/2014

Revision Record

Version 4.1 Review Date 25/09/2017

Date 18/11/2014 Author Sean Stack

Why has the document been changed - Minor version change

What has changed - 48V battery sizes reviewed and corrected (Table 6.1) and looped connection added to the Black Start requirement (Section 4.4).


Date 03/09/2014 Author Samuel Geddes / Miguel Bernardo

Update: Major revision of document


Date 18/06/2012 Author Kevin Burt

Review date extended 6 months

Version 2.2 Review Date

Date 05/09/2011 Author Kevin Burt

Document reclassified from ES to EDS


Date 10/02/2011 Author Peter Rix

Document rebranded


Date 30/04/2009 Author S P Spencer

Battery earthing arrangements revised in Section 5.6


Date 23/01/2007 Author D J Collis

Original. Replaces:

SPN ES 3-0300, EDMV10/S7/1, EDMV10/S7/2, EDMV10/S7/3, E13-DS11-1, E13-DS11-2

© UK Power Networks 2014 All rights reserved 2 of 21



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Date: 03/09/2014

Contents

1 Introduction ............................................................................................................. 5

2 References ............................................................................................................... 6

3 Definitions ................................................................................................................ 7

4 Overview .................................................................................................................. 8

4.1 110V Battery Connections for Substation Operation Equipment. ............................... 8

4.2 48V Battery Connection for Substation Communication Equipment. .......................... 8

4.3 Battery Connection for Intertripping Installations ........................................................ 9

4.4 Battery Charger System ............................................................................................ 9

4.5 Battery Loading ......................................................................................................... 9

4.6 Emergency Lighting ................................................................................................... 9

4.7 Alarms and Indications .............................................................................................. 9

5 General Requirements .......................................................................................... 10

5.1 Functions of the Equipment ..................................................................................... 10

5.2 System Environment ............................................................................................... 10

6 Technical Requirements ....................................................................................... 10

6.1 Battery Requirements .............................................................................................. 10

6.2 Battery Selection ..................................................................................................... 11

6.3 Chargers ................................................................................................................. 12

6.4 Performance Requirements ..................................................................................... 13

6.5 System Monitoring ................................................................................................... 14

6.6 Auxiliary Equipment Requirements .......................................................................... 15

6.7 Distribution Boards .................................................................................................. 16

6.8 Earthing ................................................................................................................... 17

6.9 Enclosure ................................................................................................................ 17

6.10 Enclosure Ventilation ............................................................................................... 18

7 Testing ................................................................................................................... 18

7.1 Routine Tests .......................................................................................................... 18

7.2 Type Tests .............................................................................................................. 19

7.3 Installation Test and Assessment Programme ......................................................... 19

8 Training .................................................................................................................. 20

9 Installation and Commissioning ........................................................................... 20

10 Drawings and Documentation .............................................................................. 20

10.1 Environmental Management and Quality Assurance ............................................... 20

10.2 Information Required with the Offer ......................................................................... 20

10.3 Information Required before Delivery ...................................................................... 20




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10.3.1 Installation Manual................................................................................................... 20

10.3.2 Operation and Maintenance Manual ........................................................................ 20

10.3.3 Contract Drawings ................................................................................................... 21

10.3.4 Disposal of Consumables ........................................................................................ 21

10.3.5 Health and Safety Documentation ........................................................................... 21

10.3.6 Hazardous Materials ................................................................................................ 21

10.3.7 Dismantling and Disposal ........................................................................................ 21

11 Delivery .................................................................................................................. 21




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1 Introduction This standard details UK Power Networks' requirements for the provision of new and replacement batteries, chargers and associated equipment for trip and close, communications (SCADA) and emergency lighting power supplies within primary and grid substations on the three licenced networks. EHV customer sites shall also conform to this design standard.

Where applicable battery charger systems will incorporate the Black Start Controller functionality and battery resilience levels will conform to the accepted standard.

Battery and charger systems for secondary substations, unit substations and re-closer equipment are not covered in this document.




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2 References

Black Start Recovery – Substation and SCADA Resilience.

Report by the Electricity Task Group (ETG) of the Energy Emergencies Executive Committee (E3C) – July 2010.

BS EN 50272−2:2001 Safety requirements for secondary batteries and battery installations

BS EN 60269-1 Low-voltage fuses. General requirements

BS EN 60269-2 Low-voltage fuses. Supplementary requirements for fuses for use by authorized persons (fuses mainly for industrial application)

BS EN 60529 Specification for degrees of protection provided by enclosures

BS EN 6290 Lead-acid stationary cells and batteries

BS EN ISO 14001: 1996

Environmental management systems - specification with guidance for use

BS EN ISO 9000: 2000 Management and Quality Assurance Standards

EAS 05-0001 Protection Relays

EDS 03-0030 Black Start Controller for Grid and Primary Substation Battery Charger Systems

EDS 05-9006 Telecoms Hardware for Operational Sites

EDS 05-9007 SCADA Numbering System

EDS 07-0003 Enclosed Major Substation Civil Engineering Standard

EMS 10-0002 Inspection and Maintenance Frequency Schedule

EMS 10-0005 Inspection and Maintenance of Batteries and Chargers

EN 61429/A11 Marking of secondary cells and batteries with the international recycling symbol ISO 7000-1135 and indications regarding directives 93/86/EEC and 91/157/EEC.

ENA ER G5/4 Planning levels for harmonic voltage distortion and the connection of non-linear equipment to transmission systems and distribution networks in the United Kingdom

ENA TS 48-5 Environmental Test Requirements for Protection Relays And Systems

ENA TS 50-18 Application of Ancillary Electrical Equipment

ETSI EN 300 132-2 Power supply interface at the input to telecommunications equipment; Part 2: Operated by direct current (dc)

IEC 60051 Direct Acting Indicating Analogue Electrical Measuring Instruments and Their Accessories

IEEE Standard 485-2010

Recommended Practice for Sizing Lead-Acid Batteries for Stationary Applications

VDE 0110 Pt 20 Insulation co-ordination for equipment within low voltages systems; Partial discharge tests; Application guide

VDE 0675 Pt 6 Surge arresters for use in A.C. supply systems with rated voltages ranging from 100V to 1000V




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3 Definitions ‘East of England Network’ refers to the distribution network for which UK Power Networks (EPN) plc. is the licence holder.

‘London Network’ refers to the distribution network for which UK Power Networks (LPN) plc. is the licence holder.

‘Southeast Network’ refers to the distribution network for which UK Power Networks (SPN) plc. is the licence holder.

‘Supplier’ refers to a manufacturer or other organisation supplying equipment for use on UK Power Networks’ distribution systems.

Black Start - A “Black Start” is the carefully co-ordinated restoration of generation and network demand following a partial or complete shutdown of supplies affecting all or part of the National Grid (NG) system. It results from the disconnection of generation sets from all or parts of the country’s 400kV and 275kV systems rendering the affected system effectively “dead”.

Black Start Controller in this document refers to the proposed unit which will be incorporated into UK Power Network’s grid and primary substation battery charger systems to reduce the effect of the standing load and hence the DC drain on the batteries in the event of a battery system power supply loss. Refer to EDS 03-0030 for the design detail. The driver behind the development of this solution is to meet the requirement with regard to substation protection battery resilience in Black Start situations as specified by OFGEM.

BS – British Standards

ENATS – Energy Networks Association Technical Specification

Grid Substation - Substation with a connection at the point at which Supergrid in-feed (from National Grid) is fed into UK Power Network substations.

HV Customer – A customer who’s connection to UK Power Networks electricity network is at 6.6kV and above.

IEC – Electro-technical Commission Standards

MCB – Miniature Circuit Breaker

Primary Substation – Substation with transformer step-down connection from UK Power Networks Grid Substation sites.

RTU – Remote Terminal Unit

Secondary Substation – Substation intended for local supply points or containing step down transformers from Primary Substation level

VRLA – Valve Regulated Lead Acid




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4 Overview Batteries will be VRLA design and shall be capable of operating for maximum rated lifetime in the environmental temperature range specified in EDS 07-0003.

The VRLA battery sizing shall be calculated according to details specified in this document and the appropriate size of the installation will be constructed from one or more of the standard sizes.

As an exception, Planté battery cells can be used ONLY in the event when it is a replacement of one Planté battery string as part of a dual Planté string installation.

4.1 110V Battery Connections for Substation Operation Equipment.

110V battery systems will be used for the mechanical and electrical operation of substation plant. Typically this battery will supply power to;

• Trip and Close Switchgear Auxiliaries; • Protection associated Equipment; • Black Start Controllers (where applicable).

Batteries are to be sized to meet the total load requirements for 12 hours under normal running arrangement with the associated charger out of service.

For new and existing installations the 110V battery shall be configured in 2 separate strings, each with a minimum capacity of 6 hours resilience on each string.

4.2 48V Battery Connection for Substation Communication Equipment.

A 48V battery system will be used to supply;

• Communication Equipment including SCADA RTU’s and associated panels; • Intertripping relays and associated equipment.

Batteries are to be sized to meet the total load requirements for 12 hours under normal running arrangement with the associated charger out of service. If the 48V supply is required for systems which are deemed as Black Start critical (Black Start controller functionality is incorporated in the 110V system) the battery resilience will be 72 hours.

Black Start critical systems, namely SCADA and Intertripping which do not have 72 hour resilient batteries shall be upgraded when practical. As part of substation communication upgrades, Black Start controller installation or otherwise.

For new and existing installations the 48V battery shall be configured in 2 separate strings, each with a minimum capacity of 6/36 hours resilience on each string.




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4.3 Battery Connection for Intertripping Installations

Intertripping functions will be supplied from the 48V substation battery and the Intertripping functions shall be taken into account when sizing the battery as per the resilience mentioned previous.

Intertripping battery installations will require application analysis to determine if they are providing Black Start critical function. Refer to EDS 03-0030.

Where non-isolated DC Intertripping units exist, a separate 48V dc power supply will be installed; resilience and sizing considerations shall be as explained in Section 4.2.

Where practicable older SCADA system battery installations utilising a 60V supply for Intertripping will be upgraded to 48V systems as part of battery installation upgrades, battery renewals or otherwise. This requirement does not include surge proof Intertripping systems.

4.4 Battery Charger System

All new and upgraded sites will have N+1 charging facilities. This implies that an extra charging module within the charging unit is needed, not a duplicate system.

Only Switch-mode Chargers are permitted for use in new installations on the three licensed networks within UK Power Networks.

As standard on all UK Power Networks Grid, Primary and looped EHV connection sites the 110V battery charger system will be equipped with a Black Start Controller.

4.5 Battery Loading

In all instances of load calculations, accurate loads must be specified as all error correction and design factors will be included as per IEEE 485.

4.6 Emergency Lighting

Batteries used for Emergency Lighting shall be sized to meet the total load requirement for three hours under normal running arrangements with the associated charger out of service.

4.7 Alarms and Indications

The battery charger system shall be self-monitoring, all alarms and indications will be relayed to the substation RTU as described in Section 6.4.




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5 General Requirements The equipment supplied shall comply with the latest editions of the appropriate British Standards (BS) or equivalent International Electrotechnical Commission Standards (IEC), and of Energy Networks Association Technical Specification (ENATS) except where the requirements of this standard take precedence.

5.1 Functions of the Equipment

UK Power Networks requires battery chargers and batteries to supply loads for the specified time periods at voltages of 110V, 60V, 48V, 30V and 24V systems. Batteries shall provide low voltage direct current supplies to trip and close switchgear and protection circuits, the Black Start Controller functionality, Telecontrol units, alarm signalling, emergency lighting and Intertripping supplies.

Batteries supplying communications will have a standing load and battery systems shall be designed to cope with this load. Battery systems supplying trip and close supplies will also be subject to high transient loads. This load will depend on the number of switches contained in the switch panel and the type of closing device (solenoid, motor spring or magnetic actuator).

5.2 System Environment

The equipment shall be suitable for operation under Ambient Class I conditions to ENA TS 50-18 and 48-5. No special anti-pollution measures are required. The minimum ambient temperature shall be defined as 5⁰C.

6 Technical Requirements

6.1 Battery Requirements

The installation of VRLA cells shall conform to BS 6290 Part 4 and meet the following classes:

• Performance Class 2 or better; • Durability Class 3 or better; • Safety Class 1.

Supporting documentation shall be supplied by the Supplier indicating classes of conformity for items 1, 2 and 3 above.

A statement of the lifetime performance of the batteries for operating conditions shall be supplied as part of the contract.

Each battery system shall come complete with any necessary equipment such as charge record sheets, instruction manual and advisory or warning labels.

Batteries shall be cubicle mounted and come with the necessary inter-cell and external connectors. These connectors shall be shrouded and suitably designed for any mechanical loading.

The battery system shall be provided with a means of isolation and this shall be supplied as integral equipment in the case.




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Batteries are to be recyclable and marked with the appropriate recycling symbols detailed in EN 61429/A11, together with the indication “Pb” (Lead) and the symbol for lead acid batteries.

Harmful substances like cadmium shall not be used in lead acid batteries. Where Planté batteries are required the design will meet the criteria stated above and conform to BS EN 6290-2.

The batteries shall be capable of supplying the load down to a voltage of 1.8V per cell at 25°C.

6.2 Battery Selection

In order to select a substation battery suitable for a specific site, a substation load requirement needs to be completed. This is completed in accordance with IEEE 485. The product of this result and the specific application resilience (as described in Section 4) allows the appropriate battery size required found.

To simplify the battery selection process, each battery should be made up from two or more of following sizes;

• 38Ahr; • 62Ahr; • 100Ahr; • 132Ahr; • 170Ahr; • 190Ahr.

These particular sizes relate to standard front-connected battery installations sizes. In all cases, substation batteries must be comprised of multiple strings. However, it must be noted that the cell compositions of the strings must match.

For example, it may be calculated that a substation requires an 110V battery size of 182Ahr. Therefore, to comply with Section 4.1 of this document, two strings of 100Ahr must be selected.




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The standard battery system sizes for the 48 and 110V installations respectively are shown.

Overall 48V Battery Sizes

Battery Size (Ahr) Battery Type 76 SBS B10

124 SBS B14F

200 SBS 100F

264 SBS 130

340 SBS 170F

380 SBS 190F

520 SBS 130

680 SBS 170F

760 SBS 190F

Table 6-1 - 48V Battery Sizes

Overall 110V Battery Sizes

Battery Size (Ahr) Battery Type 76 SBS B10

124 SBS B14F

200 SBS 100F

264 SBS 130

340 SBS 170F

380 SBS 190F

Table 6-2 - 110V Battery Sizes

6.3 Chargers

The battery and charger Supplier shall be responsible for charger sizing based on the required performance below.

All new and upgraded sites will have N+1 dual string Switchmode charging facilities and shall be of single phase design. If a single phase charger cannot meet load requirements, three-phase chargers may be employed. Chargers shall be temperature compensated with the float charging voltage and range designed to suit the battery type.

Chargers shall be operated from a 230V A.C. 50Hz single-phase supply or if applicable 400V A.C. 50Hz three-phase supply.

Standard chargers shall not be fitted with boost facilities or shall have any such facility disabled.

Chargers shall be temperature compensated with the float charging voltage and range designed to suit the battery type.

Chargers will be fan cooled where appropriate. Where it is felt that a fan cooled system may be in danger of malfunctioning due to the nature of the atmosphere in a particular substation, and it is felt that filtering is inappropriate, the use of convection cooling charging systems may be justified.




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The facility to provide deterministic testing for the batteries shall be provided as part of any Charger controller design. The regularity and duration of the test should be adjustable and should be executed in a manner where there is no risk to the continuity of supply to the load.

Due to issues of fault currents at operational sites, the charger shall be protected by a suitably rated surge arrester. The rating of this is to be agreed with UK Power Networks (Surge Protection device to class C to VDE 0675, in accordance with the over voltage category III to VDE 0110). This will be fitted between all live and neutral conductors and therefore provide surge protection of the rectifier module against surges. Alarm indication of activation shall be possible both visually and via a volt-free contact. This will be cabled into the charger as an alarm for common indication.

The charger control design shall be inherently current limiting. It shall be rated to supply the required standing load on the system plus an allowance as recommended by the battery supplier that provides a suitable charger rate for all conditions. Battery recharge periods shall be calculated to restore 85% capacity within 12 hours after a discharge.

For all battery/charger installations, the voltage to the distribution board shall not exceed:

• 24 volt system 28.8V; • 30 volt system 36V; • 48 volt system 57.6V; • 60 volt system 72V; • 110 volt system 129.6V.

The voltage to the battery shall not under any circumstances exceed the maximum voltage as recommended by the battery Supplier.

As stated in Section 4.4 on all UK Power Networks Grid, Primary and looped EHV connection sites the 110V trip and close battery system will be equipped with a Black Start Controller.

6.4 Performance Requirements

The charger shall provide an output voltage that does not vary by more than ±2% from 0 to 10% of the rated output and ±1% above 10% of the rated output. These conditions shall apply between ± 10% of normal A.C. supply volts. The normal float charge of the system shall be set with the charger operating at 50% rated output current and with rated input voltage. A voltmeter with an accuracy class 0.2 to IEC 60051 or BS 7194 shall be used for setting up. The float voltage should be in line with the battery supplier’s recommendations for VRLA cells. The current limit performance of the charger shall be ±2% of nominal setting over the range of the cells which is 2.21 to 2.33 volts. The equipment shall be capable of meeting its output requirements when it is fed from an A.C. main of low impedance with a frequency between 47Hz and 52Hz. The charger shall not produce interference on the A.C. input in excess of that specified in EA Engineering Recommendation G5/4.




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The charger output superimposed A.C. ripple shall not exceed the battery supplier’s recommendations, and should not exceed a maximum level of 5% of normal working D.C. voltage. In the event of the open-circuiting of the battery, the R.M.S. voltage ripple shall not exceed 12%. The Supplier shall state whether additional smoothing is required to meet this requirement. The psophometric noise level of the complete system shall not exceed the equivalent EMF of 2mV R.M.S. at a frequency of 88Hz after weighting as specified by ITU-T, and shall not exceed an EMF of 10mV for all other frequencies between 25 and 5kHz as specified in ETSI EN 300 132-2.

6.5 System Monitoring

The battery systems must incorporate the following system indications:

Within the 110V and 48V chargers:

• Supply Fail Indication - This shall provide an indication of the battery charger supply status.

• Charger Fail Alarm - Alarm to operate when output from charger is lost or is below a level capable of recharging the battery.

• High Voltage Alarm - The charger shall be fitted with over Voltage protection, which will automatically switch off the charger in the event of a voltage excursion above the high voltage alarm setting. The alarm/tripping operation shall be immune to normal surges and shall prevent spurious trips.

• Low Voltage Alarm - This shall be a two-stage alarm for both battery strings to provide an alarm at 1.9Vpc and 1.8Vpc on falling battery voltage.

• Battery Earth Fault Alarm - The battery earth fault system shall be capable of detecting low insulation resistance of all wiring connected to the battery/charger/distribution system. The battery earth fault detector shall provide an instantaneous alarm when the insulation resistance of the substation wiring connected to either pole of the system falls to 50k ohms. This shall apply at all voltages over the working range. This alarm shall be routed to its own alarm relay.

• Deterministic Testing - Its function is deterministic testing of battery performance to ensure that a load cycle can be carried out. This will also determine the condition of the battery and its interconnections. During the deterministic testing period, the charger will power down and the battery will be required to fail the test twice prior to alarm issue to ensure that switchgear operation does not lead to spurious alarms. Both strings will be load tested individually. The alarm should latch until reset by an engineer.

48V SCADA battery and charger:

• SCADA Voltage Analogue - This shall provide an indication to the control engineer of the exact battery voltage of the 48V supply.

All alarm and indications shall be monitored both locally and remotely.

The interface between the charger alarms and UK Power Networks SCADA/Telecontrol (Communication) systems shall be fail-safe volt-free contacts.

When concerned with battery system installation the following connection outline from the battery charger to the Telecontrol RTU cubicle shall be used.




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CORE No.

COLOUR FERRULE No.

FROM TERM

TO TERM

DESCRIPTION

1 RED X601 1 Alarm common

2 BLUE X603 2 AC supply to charger faulty

3 GREEN X605 3 Charger faulty

4 YELLOW X607 4 Battery abnormal HV, LV, Battery Fail (deterministic)

5 WHITE X609 5 Battery earth fault

6 BLACK --- 6 Spare

7 BROWN --- 7 Spare

8 VIOLET --- 8 Spare

6.6 Auxiliary Equipment Requirements

The complete system shall comprise the batteries, charger, Black Start controller (where applicable) and distribution boards, whether integrated or mounted separately shall be provided with all necessary protection, alarms, indicators and instruments to ensure safety and security is maintained in the event of a fault.

The system shall be provided with isolation facilities at the input and output circuits such as fuses, links and lockable switches to enable safe working on the equipment. An MCB may be provided as an alternative to switches provided locking off facilities are available on the MCB.

An MCB may not be supplied for motor, magnetic actuators of solenoid services. These must be protected by a fuse link of the appropriate rating. Services that supply relays, communication devices and other services that do not have a peak short time load may be protected by an MCB.

All fuses, links and MCBs will be installed in accordance with ENA Technical Specifications 50-18 Issue 3 Section 6.

For outgoing ways, double pole MCBs may be used.

Equipment within the cubicle that requires access for maintenance such as fuses or switches shall be easily accessible without risk to personnel.

A spare fuse shall be provided for each specific type of fuse link used within the battery charger.

Instrumentation shall be provided for readings of output voltage and current of the load and charger. Instruments shall be to IEC 60051 Class 1.5 for analogue instruments or BS 7194 Class 1.5 for digital instruments.

Protection for the enclosure will match recommendations described in BS EN 60529.

Control switches, isolating switches, pushbuttons, terminals and small wiring shall be accordance to ENATS 50-18 and shall have a design life of at least Life Class I to ENATS 50-18, Part 3.




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6.7 Distribution Boards

Distribution boards are to be supplied primarily as either a separate cubicle or in cases where space limitations are a concern, the distribution board may be supplied as an integral part of the charger and battery cubicle.

The distribution board shall supply 24, 30, 48, 60 and 110 volt D.C. supply outlets to power equipment and systems.

All systems shall be provided with fuses or MCBs suitably rated to meet the circuit standing load.

48V systems will as standard use a 6 way distribution board as a minimum. Where additional ways are required on larger installation the Supplier will facilitate individual design requirements.

110V systems will use a 12 way distribution board as a minimum. Where additional ways are required on larger installation the Supplier will facilitate individual design requirements.

Fuses must be adequately shrouded such that live terminals do not pose a safety hazard. If suitably shrouded fuses cannot be used then an MCB should be fitted.

Distribution ways on the cubicle shall be labelled to suit the contract requirements. Where supplies of different current ratings are required the fuse carriers will be grouped by fuse rating i.e. all 32 amp services together.

32 amp Fuse Carriers and MCBs shall be designed to provide connection of cables down to 1.5mm2.

Fuse carriers shall be provided with a fuse at the specified ratings and a spare fuse link for each rating specified which will be in accordance with BS EN 60269-1 and BS EN 60269-2.

There shall be provision for both top and bottom cable entry on all separate distribution boards.

Each distribution board shall be provided with a suitable plug and socket assembly (socket to be provided loose) to allow the connection of an external battery packs to allow support of the load in the case of a battery or charger fault.




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6.8 Earthing

The 110V battery system shall not be directly earthed. All metal cubicles, distribution boards and metal enclosure equipment shall be bonded to earth. The overall system is required to detect earth faults by means of earth leakage equipment.

Some 48V battery systems for SCADA have in the past been solidly earthed at the positive busbar especially at sites with an NG interface. New systems shall not be directly earthed and will have a system of earth fault alarm in line with systems at other voltages. This is in line with the current practice in all three license areas and current telecommunications preferences.

6.9 Enclosure

All cubicles shall have a 40-year service life.

The battery cubicle shall provide adequate access and storage space to allow inspection and maintenance of the battery cells and charger.

The cubicle shall allow the use of a range of currently available cells from major battery manufactures.

The battery cubicle shall be designed to minimise heat build-up during normal operation of the system.

Sufficient space at any point in the horizontal plane should be available to allow free flow of air. As a general guide, a minimum gap of 10mm is recommended between any two adjacent faces of cells or units within the area occupied by the battery. It is further recommended that load bearing shelves or racks should allow free movement of air in a vertical direction within the rack or cubicle.

Access to contents of the battery cubicle shall be through a door with a suitable locking mechanism to allow for easy access for maintenance and testing.

Cubicles shall suit installation on a solid floor, above a cable trench or on a computer floor with removable floor panels.

Ground mounted cubicles shall house the charger and Black Start controller at a suitable height to allow easy inspection and maintenance.

Each cubicle shall be complete with all the necessary apparatus such as markers, labels, gland plates etc.

The equipment shall be safe and capable of being secured against unauthorised entry and all exposed wiring shall be shrouded.

There shall be provision for both top and bottom cable entry on all cubicles. This shall be via 3mm thick gland plates.

In the case of site flood, the charger, controller and battery cubicles shall be marked to indicate the maximum safe height water may reach without electrical failure or fault. A clear marking line visible once the cubicle is installed shall be provided and marked ‘Flood Level – do not re-energise if water exceeds this height, inspect and test unit prior to use’.




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6.10 Enclosure Ventilation

Suitable ventilation will provide an ambient temperate to ensure the maximum lifespan of the battery as specified by the Supplier.

The environment in which a battery is to be stored will adhere to the specifications laid out in Section 8.2 to 8.7 of British Standard EN 50272−2:2001.

This document states that the purpose of ventilating a battery location or enclosure is to maintain the hydrogen concentration below 4% Lower Explosion Limit (LEL) threshold. Battery locations and enclosures are to be considered as safe from explosions, when by natural or forced ventilation the concentration of hydrogen is kept below this safe limit.

The Supplier shall provide the battery current determined from an overcharge gas emission test at 2.4 volts per cell.

7 Testing

7.1 Routine Tests

Routine tests on the charger and distribution system shall be carried out at the supplier works as part of the acceptance procedure. These tests shall include tests at maximum, minimum and rated A.C. volts with rated frequency at 10%, 50% and 100% of the rated output of the charger and these shall be recorded on the test certificate. The following features shall also be demonstrated;

• Current limit; • High and low volt alarms; • Deterministic Testing; • Charger fail alarm; • Temperature compensation; • Earth fault alarms (30/48/110 volt only).

Cubicles shall be inspected to ensure adequate shrouding of live terminations, conductors and exposed components, and that access can be gained safely to fuse, links, MCBs and maintenance points inside.

All circuits connected to the A.C. input shall withstand 2kV RMS, 50Hz A.C. test voltage between all terminals and earth, and between terminals of electrically separate circuits, after which the resistance shall be measured and shall be not less than 20Mohms between any terminal and earth, or between terminals of electrically separate circuits.

The insulation of each transformer between each winding, screen, core and frame shall also withstand the above test.




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7.2 Type Tests

Type Registration and Routine tests on the battery shall be carried out in accordance with BS 6290. Testing shall be carried out on the complete or part-supplied system.

1. The electronic circuitry shall be tested by the application of 6kV full standard lightning impulse with 1.2/50ms characteristics as defined in IEC 60-1. Three positive and three negative impulses shall be applied as follows:

• Between the output terminals with the battery connected; • Between the output terminals connected together and earth, with the input terminals

earthed; • Between the input terminals connected together and earth, with output terminals earthed.

2. The following tests shall also be carried out in accordance with BS6290:

• Drop Test; • Spark Test; • H.F. Disturbance Test; • Dry Heat Test; • Low Temperature Test; • Soak Test.

7.3 Installation Test and Assessment Programme

A test and assessment programme shall be undertaken by UK Power Networks to ensure the operational suitability of each item of plant offered by the suppliers.

A unit shall be delivered and collected at the suppliers cost to our nominated plant store. The unit shall be collected by the supplier at the end of the test program from our nominated plant store.

Each supplier shall provide one fully assembled:

• Battery Charger and associated equipment. (Note: A full battery pack is not required, but sample battery cells and terminations shall be provided).

Each supplier shall also supply:

• Full installation and dismantling instructions for unit. • Details of maintenance requirements. • Any additional special tools or equipment required to allow installation, operation and de-

commissioning of the suppliers equipment.




Version: 4.1

Date: 03/09/2014

8 Training The Supplier shall provide all necessary training aids, as agreed with UK Power Networks. This may include training on site or at the manufacturer’s works.

9 Installation and Commissioning Where required, the Supplier shall install and pre-commission the equipment ready for UK Power Networks to commission and set to service.

10 Drawings and Documentation

10.1 Environmental Management and Quality Assurance

The Supplier shall have quality assurance arrangements which conform to BS EN ISO 9000: 2000, “Management and Quality Assurance Standards”

The Supplier shall have environmental management arrangements which conform to BS EN ISO 14001: 2004, “Environmental management systems - specification with guidance for use”.

10.2 Information Required with the Offer

The following information is required with the offer:

• General arrangement drawings of the equipment; • Details of any significant considerations and procedures that may have an impact on

health and safety matters; • The Supplier’s Environmental Policy; • Details of the appropriate training necessary to enable the Company’s staff to safely

install; operate and maintain the equipment.

10.3 Information Required before Delivery

10.3.1 Installation Manual

An installation manual for the equipment shall be provided. Further additional copies of the manual, as may be reasonably required by the Company, shall be supplied on request. An electronic version of the manual, in pdf format, shall also be supplied.

10.3.2 Operation and Maintenance Manual

Maintenance of the 48V and 110V battery string will coincide with maintenance schedule for Batteries at Grid/Primary substations P17 and P18 where applicable. Please refer to EMS 10-0002 for reference and EMS 10-0005 for the current UK Power Networks maintenance procedure. In the event that EMS 10-0005 is not suitable for the Battery and Charger system provided the Supplier shall inform UK Power Networks prior to supply.

An operations and maintenance manual shall be provided for each significant piece of apparatus. The document shall provide the information necessary to allow safe operation and maintenance. In particular the manual shall list recommended methods of safely working at heights (where appropriate) and all normal activities associated with the apparatus. Further additional copies of the manuals, as may be reasonably required by the Company, shall be supplied on request. An electronic version of the manual, in pdf format, shall also be supplied.




Version: 4.1

Date: 03/09/2014

10.3.3 Contract Drawings

A complete set of contract drawings shall be supplied. These shall include:

• Outline general arrangement including foundation layout, and minimum enclosure and clearance dimensions;

• Schematic diagrams and wiring diagrams; • The drawings shall be provided electronically in Microstation format (DWG or DXF).

10.3.4 Disposal of Consumables

The disposal of all packaging and installation waste shall be the responsibility of the supplier and shall be disposed of in accordance with current legal requirements.

10.3.5 Health and Safety Documentation

The Supplier is required to provide Health and Safety documentation by selecting the appropriate sections from the list below, relevant to the Offer.

10.3.6 Hazardous Materials

A detailed list of hazardous materials associated with the equipment. The document shall contain all details of any necessary precautions for the safe use, maintenance and removal of the materials in the future.

10.3.7 Dismantling and Disposal

A schedule of dismantling procedures shall be supplied which documents each significant piece of apparatus and detail how the item should be safely dismantled and disposed of at the end of its life.

Where existing equipment is being replaced it shall be the responsibility of the supplier to dispose of batteries, chargers and any associated equipment and shall be disposed of in accordance with current legal requirements.

The supplier shall supply details of the relevant requirements to meet the current legislation including COSHH, LOLA and PURE Regulations.

11 Delivery The equipment shall be delivered complete and ready for service, except where set out in this specification, and shall be suitably and adequately protected and supported during transit and storage.


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