Design

Requirement
LFP ESS deployment

April 2023

ISSUED BY
Husk Power Systems

REPRESENTATIVE
Soham Mallick
[email protected]
+91-9330146880
 Introduction & Background
This document includes the requirements of designing LFP ESS for Husk Power System.
We need to have a usable battery capacity of 72 kWh (which excludes the inversion loss
by the inverter). The system has to have an independent module-level operation along
with each cell monitoring and active balancing among the cells for ensuring the usage of
complete capacity (with 80% DoD) of the whole system during both charging and
discharging uniformly.
We are trying to avoid the paralleling of the battery bank to avoid the improper balancing
and distribution of charge among the battery banks during charging and discharging, as
per our previous experience with the Li-ion pilot. We can have an option to increase the
system nominal DC voltage above 240V to improve performance and cost effectiveness.
The application of the ESS as the battery backup system for HMG mainly to cater loads
during the non-solar hours and to act as an energy buffer during variable demand and
generation situations.

Description of the existing system

The following is the description of our existing system -

1. For the charging of the battery system we have -

a. 30 kW MPPT based solar charger with 10% allowable overload.
b. 25 kW Biomass converter (secondary source of charge)
Both systems can charge the battery together or independently up to their capacity by a
hybrid solar inverter.

2. For the discharging of the battery system we have -

a. 40 kW of solar inverter having three times dc input capacity with
the following overloading provisions-
(i). 150%/200% for 60 sec / 5 sec
(ii). Momentary overload of 450% for 1 sec
3. We have a very dynamic charging available for our cases strongly dependent
on Solar availability. Also, the load demand pattern is very dynamic throughout
the day.

4. We have an IoT based Remote Monitoring System available at Plant which

has remotely read and write provision through RS485 or TCP/IP Modbus
protocol.

Specification Sheet

Please fill out the specification sheet below.

Serial Specification/Details Cell/ Value/ Unit Supportive

No. Module/ Description Document/
Battery Certificate
Level As proof

1 Nominal Voltage/ cell Cell V

2 Rated Capacity/cell Cell Ah

3 Nominal Voltage Battery V

(system)

4 End of charge voltage Battery V

(system)

5 End of discharge Battery V

voltage (system)

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 6 Voltage at 20% SOC Battery V

7 System arrangement Battery

Single Cell Cell mm*mm*mm

8 Dimension (L*W*H)

9 Single Cell Weight Cell Kg

Battery Battery mm*mm*mm

10 System
Dimension

11 Weight of a module Module Kg

12 Module Energy Module Wh/kg

Density
(Capacity of
module/module
weight)

13 Maximum Battery V
Charging Voltage
(Cell)

14 Minimum Battery V
Discharging Voltage
(Cell)

15 Standard Max Battery A

Charge Current upto
95% SoC

16 Standard Min Battery A

Charge Current
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 Battery A
Standard Max
17
continuous Discharge
Current upto 20% soc

18 Standard Min Battery A

Discharge Current

Max instantaneous Battery

Charge/ discharge
19
current with time
duration

20 Cell minimum Cell mΩ

internal resistance

21 Cell maximum Cell mΩ

internal resistance

22 Charging working Battery

◦ c to ◦c
temperature range

23 Discharging working Battery

◦ c to ◦c
temperature range

Derating of cycle cycles

life at different
elevated
24
temperature
(mention at
30 degc, 40 degc,
45 degc)

25 Cell life cycle up to Cell

30◦c temperature for

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 i)80% SOH, 80%
DOD >=4000 cycles
(required)

ii) 80% SOH, 100%

DOD Cycle

iii) 70% SOH, 80%

DOD Cycle

iv) 70% SOH, 100%

DOD Cycle

26.a Round Trip Efficiency Battery

27.b AH Efficiency Battery

26 Maximum time span Battery days

between two
consecutive full
charge w/o
affecting cell
performance

28 Cell balancing Module

during charging and
discharging
(mechanism
description)

(<1% unbalance
across 20% to 100%
SOC (required))
29 Volumetric Density Battery Wh/L

30 Gravimetric Density Battery Wh/g

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 Battery Management System requirements

The following are the list of required features for the Battery Management System.
1. Monitoring Level -
Mention the detailed architecture of the monitoring level of the system that is
from cell level monitoring to whole system monitoring.
2. Below parameters are mandatory to monitor -
a. Voltage - Cell level monitoring
b. Current - Cell level monitoring
c. Temperature - Cell level monitoring
d. Amperehour (charge and discharge) - Module-level monitoring
e. Energy - Module-level monitoring
f. Voltage (avg,max,min) - Module-level monitoring
g. Current (avg, max, min) - Module-level monitoring
h. Temperature (avg, max, min) - Module-level monitoring
i. Voltage (avg,max,min) - System-level monitoring
j. Current (avg, max, min) - System-level monitoring
k. Temperature (avg, max, min) - System-level monitoring
l. SOC, SOH, SOU(State of utilization), Lifecycle - System-level monitoring //
if there is more than one rack/string, provide that level too.

3. Human Machine Interface -

● Display Parameters: All the measured parameters from the cell level
to system level should be displayed on the display interface
● Data Logging: All the measured data should be stored in the BMS internal
memory for at least one year, which can be easily accessed/downloaded
into a computer by HDMI / LAN/USB interface.
● Communication Interface: All measured data can also be read in real-
time by the Modbus communication protocol (RS485 / TCP-IP).

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 4. Protection Levels -
● There should be 3 defined protection levels namely “Alarm, Protection 1
and Protection 2”.
● The alarm will generate an alert or warning in the display and
communication interface.
● At Protection 1 Charging/Discharging loop should be disconnected with
indicating on BMS display until recovery achieves for the same
● At Protection 2 Circuit breaker should be tripped with indicating on BMS
display with fault indication which should be recovered by manually
Level Protection Protection Value Unit Remarks
Type Level

Cell Alarm V

(Prismatic OR Over Voltage

Cylindrical) Protection 1 V

Protection 2 V

Recovery V

Under Alarm V
Voltage
Protection 1 V

Protection 2 V

Recovery V

Module Alarm V

Over Voltage Protection 1 V

Protection 2 V

Recovery V

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 Under Alarm V
Voltage
Protection 1 V

Protection 2 V

Recovery V

Battery Bank Alarm V

Over Voltage Protection 1 V

Protection 2 V

Recovery V

Under Alarm V
Voltage
Protection 1 V

Protection 2 V

Recovery

Battery Bank Alarm A

Charging Protection 1
Current Limit A

Protection 2 A

Recovery
A

Battery Bank Alarm A

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 Protection 1
Discharging A
Current Limit Protection 2 A

Recovery
A

Battery Bank Low Alarm %

SOC
Protection 1
%

Recovery
%

Battery Alarm °c
Charging
High Charge Protection 1
Temperature °c

Protection 2
°c

Recovery
°c

Alarm
°c
Low Charge Protection 1
Temperature °c

Protection 2
°c

Recovery
°c

Battery Alarm
Discharging °c
High
Protection 1
Discharge °c
Temperature
Protection 2
°c

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 Recovery
°c

Alarm
°c
Low
Protection 1
Discharge °c
Temperature
Protection 2
°c

Recovery
°c

5. Protection from Thermal Runaway -

Mention in detail what special features are included to protect the system from thermal
runaway conditions including the decomposition temperature, and heat release parameters
at the end of life.

6. Special Provision -
a. If one or more cells goes to
I. Failure or
Ii. Undervoltage beyond limit or
Iii. Over-temperature beyond limit
The specific module can be bypassed for those circumstances (automatically) and
will continue to operate at reduced capacity until those cells are recovered from their
conditions or replaced (extreme cases).

b. If there is more than one string operating in parallel, those strings should be
operated independently so that the system capacity can be easily decreased
or increased (switching on/off strings) without affecting the system overall
performance.

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 Certifications, Charts and Drawings
The following certifications need to be provided at least
1. UN 38.3: 2015
2. IEC 62133-2: 2017
3. IEC 626194, IEC 62620
4. CE (Battery)
5. UL 9540A
6. UL 1642: 2013
The following graphs need to be provided at least
1. Voltage vs SOC during charging and discharging at different C rates
2. SOC vs time during charging and discharging at different C rates.
3. Cell Degradation over Lifecycle test
The following drawings need to be provided at least
1. 3D model
2. GA drawing with mounting arrangement

Failure and Replacement

Mention in details the following -

1. MTBF of the cells and system
2. Replacement procedure with minimum and maximum time for replacement
while failure
3. SOP and precautions to be followed to avoid the failure with their reasons.

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