DC Backup System Protection Coordination

BATTERY & DC BACKUP SYSTEM PROTECTION COORDINATION
Hassam Nasrat P.Eng.
8/28/2011
Primax Technologies Inc.
Protection Coordination AGAIN? Its been already well covered by many studies and books...
Introduction
8/28/2011 Primax Technologies Inc. 2
Very simple: 99% of all available literature and standards are about AC applications. Very few cover DC faults.
Introduction
In this presentation, Well focus on Fault (short circuit) coordination assuming that overload protection is much easier to define and manage. Challenge Better understand the whole DC backup system fault behaviour in order to get to a conclusion for safe and reliable solution.
Introduction
In typical DC backup systems multiple sources of energy are: connected in parallel simultaneously contributing into the fault Each has different time constant and amplitude Fault effect reflected on AC mains must be taken in consideration. Ex. 2 chargers, 1 or more batteries, inductive loads, fully charged capacitors....
Rational
Once breaking current of each source is defined, one has to refer to the country standard to specify the required components IEC std ratings and requirements may vary from CSA, UL, IEEE, NFPA...
Rule
Fuses, circuit breakers, switches, bus bars, cables and other equipment need to operate safely and reliably during fault: Breakers and Fuses Need to open SELECTIVELY Cables, switches, bus bars... Need to WITHSTAND the fault energy
Bottom line
For the purpose of this discussion we define the following: Fault: refers to a very low impedance path created when both polarity conductors are shorted.
Failure: refers to over-current: Ex. Failing load, leakage in battery or DC source has lost regulation

As always, Ohms law applies: I = V / Z
Z: individual component impedance including interconnecting cable resistance.
Basics
During fault evolution: System voltage decays gradually. The decay rate is related to impedance rate-of-change of all parallel sources over the period of time before that protection devices open. This calculation is less accurate than the initial fault current.
Steady state fault

At the occurrence of a fault, a badly coordinated protection device may lead to: Device failure: Circuit breaker contacts may weld during opening, so the fault is not interrupted

Explosion: the device will explode due to the energy available during the fault arcing. Fire: due to the arc ignition of material during the contact opening Injury or death: Operators will be operating in unsafe environment. Note: Arc flash hazard level is directly proportional to the duration of the arc fault.
Effects
To define minimum protection fault current ratings, we need to evaluate the contribution in the fault of each of the DC components
Energy sources
Lets looks first to typical DC backup system layouts:
Typical layouts
Typical layout
Redundant layout
Redundant complex layout

Typical nuclear layout

Typical battery charger layout

Battery Charger output under fault

Contribution of different DC components

Depending on the battery technology, plate thickness and number, specific gravity (in the case of Lead acid batteries) available fault current may vary. Check with battery manufacturers for the exact fault current. Time constant: consider 10ms
Battery
Typical 350AH battery fault current at its terminals: VLA 0.33 thick Flat calcium plate battery with 1.215 SG: 3200A

Tubular VLA 0.35 thick plate battery with 1.215 SG: 3400A AGM VRLA : 4361A Gel VRLA: 3750A Ni-Cd Medium performance: 3200A
Battery example
Capacitors are a source of large instantaneous currents

Consider time constant 10 ms Ex. 8 x 10,000uF-200VDC- ESR:20m
with line impedance of 0.1
Filter Capacitors
8 x 10,000uF200VDC ESR:20m with line impedance of 0.1

C (uF) 80 000 R( ) 0,1 Vo 136 RC(s) 0,008 Vc Vo . e(-t/RC) Imax(A) Vo/R 1360 Q (uC) I(A) CVo(e-t/RC)(Voe(-t/RC))/R 10880000 1360 at t=0 I at 1 RC I at 2RC 1360 500 184 A A A
t=RC(s) t=2 RC(s)
0,008 0,016
Capacitor discharge case

Magnitude of faults depends mainly on:

AC mains impedance Power transformer impedance Inductive filter design Other series components
As a rule of thumb take 15-20 times the full current rating time constant 25ms Ex. 500A battery charger with a 3.5% Z transformer impedance may deliver up to 10 000A during a short circuit until its own protection gets into action to interrupt.
Charger/rectifier
Main concern is DC motors: They operate switchgear, turbine lube pumps During deceleration, motors act as a generators contributing in the short circuit.
-
Consider that all motors are connected and running at the time of the fault Typical motor armature has large L/R time constant 20-60ms lower di/dt longer time to clear protection Rule of thumb: Use 4 times of running FLA
Inductive loads
Its not bad to have high fault availability from the source to efficiently perform selective clearance. So if the protection fuse or breaker has larger I2t than what the source can provide, then this protection cannot clear its load fault. Ex. Switchmode power supplies provide fast current limiting and current foldback feature leading to a challenge in clearing faults.
Note
Fuse or circuit breaker? Both provide over-current, short circuit protection, selective coordination and arc flash protection. Breakers can provide remote monitoring, adjustability, reset and control. Semiconductor fuses for ex. can provide subcycle fault protection and long term overload capacity
Protection
DC Interrupting KA Flexibility (optional features) Adjustable Resettable Reliability (maintenance) Arc flash protection
Fuses ++ + ++ + delay trip must be at minimum
Circuit Breakers +++++ +++ ++++ ++++
Fuse or circuit breaker?

Fuse data
Fuse block data

Fuse coordination curves

Circuit Breaker Data

Circuit Breaker Data

HKD400 HJD250
At first, one can think that protection is perfect: 250A CB is fed from 400A main CB!!
Case: DC protection coordination
Breakers coordination
3500ASC
Total Fault at X: 2x3500A + 2x7250A = 21500A + inductive

HJD250 HKD400 HKD400
7250ASC
7250ASC
22kADC breakers X
To Inverter
Case
Soft start
If fault occurs during the soft start period of the rectifiers, available currents can be limited to lower value and chargers might shut down.
Inherent current limit

Depending on the fault evolution over time, rectifiers may or may not limit their output current during faults
Ground Leakage alarms

in a floating DC system, this alarm will alert user for 1st polarity ground leakage which may not cause operation failure although it can be a safety hazard. A 2nd polarity ground leakage may cause high impedance fault through the ground.
Connection cables
Interconnecting cable impedance reduces the fault current. This depends on their material, cross section and length. In general, battery interconnecting cable voltage drop is accounted in the short circuit capabilities of the batteries. Ex. 4/0-259 strands copper cable has a DC resistance of 0.15 /km.
Other protection considerations

IEEE 946: Recommended Practice for the Design of DC Auxiliary Power Systems for Generating Stations

IEEE 1375: Guide for the Protection of Stationary Battery Systems IEEE 1584 empirical equations are used to calculate arc-flash levels
ANSI/IEEE C37.40 (1993), "Standard Service Conditions and Definitions for High-Voltage Fuses, Distribution Enclosed Single-Pole Air Switches, Fuse Disconnecting Switches, and Accessories"

IEC 60909: Short-circuit currents in three-phase-a.c. systems IEC 60947: Low-voltage switchgear and control gear IEC 60127 family: requirements applicable to fuses
UL 489 and CSA 22.2-5-09 Harmonized Standards: Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures
Few applicable standards

During faults, DC system components response will be non linear, resulting into complicated behaviour. Consequently, rule of thumb and past experience might be needed to define breaking currents.
Conclusion
However, in special or large applications, Rules of thumb might lead to overestimated values affecting the size and cost of the installation. So, in this case, more accurate assumptions and calculations must be made.
Conclusion
Take all precautions to properly define your equipment protection and selectivity: ASK FOR

Breaking capacity of protection device
Fault capabilities of all connected energy sources Require professionals with relevant experience and background to help
Conclusion
QUESTIONS?
8/28/2011
42
Thank you !
8/28/2011
43

DC Backup System Protection Coordination

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BATTERY & DC BACKUP SYSTEM PROTECTION COORDINATION

Hassam Nasrat P.Eng.

Primax Technologies Inc.

As always, Ohms law applies: I = V / Z

Z: individual component impedance including interconnecting cable resistance.

Steady state fault

Lets looks first to typical DC backup system layouts:

Redundant complex layout

Typical nuclear layout

Typical battery charger layout

Battery Charger output under fault

Contribution of different DC components

Capacitors are a source of large instantaneous currents

Consider time constant 10 ms Ex. 8 x 10,000uF-200VDC- ESR:20m

with line impedance of 0.1

8 x 10,000uF200VDC ESR:20m with line impedance of 0.1

t=RC(s) t=2 RC(s)

Capacitor discharge case

Magnitude of faults depends mainly on:

Fuses ++ + ++ + delay trip must be at minimum

Circuit Breakers +++++ +++ ++++ ++++

Fuse or circuit breaker?

Fuse block data

Fuse coordination curves

Circuit Breaker Data

Circuit Breaker Data

Total Fault at X: 2x3500A + 2x7250A = 21500A + inductive

Inherent current limit

Ground Leakage alarms

Other protection considerations

Few applicable standards

Breaking capacity of protection device

Primax Technologies Inc.

Primax Technologies Inc.

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