When installing a large-scale battery system, safety is not an option, but an absolute requirement. For iwell, HyTEPS realised a crucial Arc Flash Compliance study, in which we eliminated potential life-threatening risks and drastically reduced shutdown times. We provided the technical assurance needed to ensure a safe energy transition.
The energy transition calls for innovative solutions, such as iwell's impressive 'MegaCube' at Eneco's site in Utrecht Lage Weide. With a capacity of 14,000 kWh, this system plays a key role in balancing the power grid and reducing gas consumption. However, such huge capacities carry significant, often invisible risks. The integration of six containers with battery systems and three transformers connected directly to medium voltage creates a complex electrical infrastructure. The challenge for iwell was clear: how do we ensure the absolute safety of personnel and equipment in an environment where huge amounts of energy can be released in milliseconds?
The need for security was reinforced by the stringent requirements of supplier Tesla. Before any maintenance work was allowed to take place, a detailed arc calculation was required. This is not a bureaucratic formality, but an essential safety measure to prevent fatal injuries caused by arc flash. Uncertainty about the exact energy levels in the event of a potential short circuit was a roadblock to safe management. As Technical Project Manager Kolijn Venema of iwell points out:
"You do have a kind of moral obligation to carry that out, I think, for the personal safety of people working around and on the installations."
Based on the technical documents, HyTEPS built a model to simulate the behaviour of the protection systems in the installation. The aim was to calculate exactly how much energy is released during a short circuit and whether this could lead to personal injury. This simulation showed that the existing settings of the protection circuit breakers and policies needed to be adjusted to prevent an excessive amount of electrical energy from spilling over to a person.
Christan van Dorst, Manager of Technical Engineering, noted that the calculated arc energy was too high due to sub-optimal settings. "In the case of an arc, longer delays associated with the short-circuit tripping time can lead to dangerous levels of arc energy being released from a distribution box," he explained. HyTEPS then made a concrete proposal to reduce this energy.
The advised proposals were implemented immediately: the new breaker 'trip' times have been reduced to 0.12s and 0.08s, where previously they were 0.48s and 0.27s. These reductions of 75% and 70% ensure shorter trip times, reducing energy levels during an arc while maintaining coordination between protective devices. This makes the cabinets safer and, in the event of an incident, the right device is always switched off correctly.
In addition to the technical modifications, arc labels have been installed and the Personal Protective Equipment (PPE) required per cabinet has been defined for safe working. Kolijn Venema of iwell concludes, "HyTEPS definitely helped us improve the security concept of the installation. It was surprising in a way, because we had assumed that security settings would ensure good safety for everyone. But so according to the arc study, that turned out to be not enough".
Flame arcs are a real risk for any industrial plant. Leave nothing to chance. Our specialists analyse your risks and guarantee a safe working environment through compliance with the strictest standards.
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