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Technical Proposal for Global Power Source group September 5th, 2018

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Kokam Technical Proposal

500kVA-10min UPS Project

For Global Power Source group in India


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Document Information

Title Technical Proposal Prepared By Kokam Co., Ltd.

Date of Release September 5th, 2018 Author Moon-Soo Kim

Revision No. 1.1 Prepared For Global Power Source Group

Status Release Confidentiality Confidential

Notice of Copyright

Copyright© 2015 Kokam Co., Ltd. All rights reserved. No part of this document may be reproduced in any form

or distributed to third parties without the written consent of Kokam Co., Ltd.

Head Office Information

• Address: 30-78, Gyeongsu-daero, 1220beon-gil, Jangan-gu, Suwon-si, Gyeonggi-do,

• South Korea

• Tel: +82-31-3620-100

Additional Information

• Email: [email protected]

• Website: www.kokam.com

Revision History

Version Status Date Written by Modification

1 Release 2018-Sep-05 Moon-Soo Kim

1.1 Revision 2018-Sep-06 Moon-Soo Kim DC Voltage for 3-pole

DISCLAIMERS OF WARRANTIES

ALL MATERIALS AND SERVICES ON THIS DOCUMENT ARE PROVIDED “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OR THE WARRANTY OF NON-INFRINGEMENT. THIS DOCUMENT COULD INCLUDE TECHNICAL OR OTHER MISTAKES, INACCURACIES OR TYPOGRAPHICAL ERRORS. KOKAM ASSUMES NO RESPONSIBILITY FOR ERRORS OR OMISSIONS IN THE INFORMATION, DOCUMENTS, SOFTWARE, MATERIALS AND/OR SERVICES WHICH ARE REFERENCED BY OR LINKED TO THIS DOCUMENT. KOKAM DOES NOT GRANT ANY EXPRESS OR IMPLIED RIGHT TO ANY PERSON OR BUSINESS ENTITY UNDER ANY PATENTS, COPYRIGHTS, TRADEMARKS, OR TRADE SECRET INFORMATION WITH RESPECT TO THE MATERIALS AND SERVICES. NO PORTION OF THE INFORMATION OR DOCUMENTS MAY BE REPRODUCED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN CONSENT OF KOKAM. IN NO EVENT SHALL KOKAM BE LIABLE TO ANY PERSON OR BUSINESS ENTITY FOR ANY SPECIAL, PUNITIVE, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES BASED ON ANY USE OF THIS DOCUMENT.

mailto:[email protected]


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I. EXECUTIVE SUMMARY ............................................................................................................ 4

1. Company Introduction .................................................................................................................................. 6

1.1. Kokam Battery Applications ...................................................................................................................... 7

1.2. Kokam Battery Characteristics ................................................................................................................. 8

1. Advantage of Cell ................................................................................................................................ 8

1.3. Cell Certifications .................................................................................................................................... 11

1.4. ESS/UPS References ............................................................................................................................. 12

1.5. Terminology ............................................................................................................................................ 13

2. Battery System for ESS/UPS ...................................................................................................................... 14

2.1. Kokam Features ..................................................................................................................................... 14

2.2. Battery Specification ............................................................................................................................... 15

2.2.1. Cell ................................................................................................................................................... 15

2.2.3. Rack ........................................................................................................................................... 17

2.2.4. System ....................................................................................................................................... 19

2.3. Battery Management System ................................................................................................................. 21

2.3.1. Module BMS .................................................................................................................................... 21

2.3.2. Rack BMS ........................................................................................................................................ 22

2.3.3. BMS Monitoring Software ................................................................................................................ 22

3. Testing Program .......................................................................................................................................... 23

3.1. FAT Type Test ........................................................................................................................................ 23

3.1.1. Type Test (or Factory Test) ............................................................................................................. 23

3.1.2. Individual Test List ........................................................................................................................... 23

3.1.3. Site Test List (Not included in the scope of offer) ............................................................................ 23

4. Maintenance and Training .......................................................................................................................... 24

4.1. Maintenance ........................................................................................................................................... 24

4.1.1. Storage Batteries ............................................................................................................................. 24

4.1.1.1. Preventive Maintenance ............................................................................................................... 24

4.1.1.1.1. Corrective Maintenance ......................................................................................................... 25

4.1.2. Objective .......................................................................................................................................... 25

4.1.3. Organization .................................................................................................................................... 25

4.2. Training ................................................................................................................................................... 26

4.2.1. Contents .......................................................................................................................................... 26

5. Appendix (Detailed References) ............................................................................................................ 27

5.1. Spinning Reserve & Frequency Regulation References ................................................................... 27

5.2. Additional Reference List for ESS/PCS ............................................................................................. 31


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Executive Summary Kokam has a long list of outstanding references in multi MWh scale installation in many parts of the globe.

With every installation Kokam has improved upon its design and continuously strived to build the best

ESS/UPS in the market. As a result, the latest Kokam ESS/UPS is the most sophisticated and complete

solution in the market.

Kokam will supply and install a high quality battery system and ensure reliable operation of the battery system.

In addition, Kokam will provide maintenance and operation support, optimal customer service, optional know-

how to ensure the optimized solution of the ESS/UPS.

Lithium battery solution of Kokam offers the following benefits for your UPS system:

Identical systems with modular configuration, provides the ability to operate the system with reduced

capacity during maintenance periods

Lower space than VRLA

Overall lower losses (higher efficiency).

Totally enclosed electronics enclosure, which seals any external contaminants entering electronic

components.

Our system is designed to achieve the required duty cycle over the product lifetime, whilst keeping the state of

charge within recommended operational levels. These optimized mixes are considered safety, charge &

discharge performance, longevity, efficiency, power density & total cost of ownership.


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Technical Summary

Category Information Remarks

Battery Rating 500kVA-10min PF0.9(400kW), Battery Installed Capacity 111kWh 3-pole

Battery Chemistry Lithium Ion Battery (NMC Based)

Battery Calendar

& Cycle Lifetime

15 Years with remaining capacity for 500kVA-10min, PF0.9 discharge at 18~28Degrees in Celsius

Usable Capacity At least 66.6kWh @ AC terminal

Safety Feature BMS (Battery Management System) at Module, Rack and System

Level.

Inverter Technology Global Power Source Group

(Not within Kokam Scope of Work)

Control System Technology

Monitoring by BMS (Battery Management System), which is

controlled by UPS inverter commands

Cooling Battery should be cooled with its HVAC(Heat, Ventilation and Air Conditioning, Not within Kokam Scope of Work)

At 18~28 Degrees in Celsius

Fire Protection Fire Suppression System is included into Battery Enclosure

Aux Power Consumption

100W (Max. 400W) Environment-dependent

Maintenance

Requirement Annual Maintenance recommended under separate contract

Design, Manufacturing and Delivery Timelines

– 12 weeks EXW after receipt of Purchasing Order

Pricing, delivery and payment terms, and other terms and conditions

– Please refer to the commercial proposal, to be provided separately

Warranty & Maintenance

Category Information Remarks

Product Warranty

5 years Extended warranty available, on request

Lifetime Guarantee

15 years with remaining capacity, at 18~28 Degrees in Celsius

Please consult Kokam with the actual load profile of UPS

Availability Guarantee

Availability Guarantee is available under separate Maintenance Contract


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1. Company Introduction

As a globally acknowledged battery manufacturer and battery solution provider with 28 years of experience,

Kokam strives to develop customer-centered, reliable, safe, high performing and eco-friendly battery solution.

Kokam began as a company focused in manufacturing polymer processing

equipment, expanded its business to designing and manufacturing Lithium-

ion/Polymer secondary batteries in the late 90's, and succeeded in developing

the world's first high capacity Lithium Polymer batteries. Since then, Kokam's

state-of-the-art battery solutions have been widely utilized across the world

and recognized for their superior characteristics.

Kokam not only has impressive production capabilities, but also cell and pack

assembly plant (XALT) in the US manufacturing 700MWh annual production

capacity. With over 150 battery related patents and 652MWh proven field

performance in ESS, UPS, EV, Marine, Aerospace, Telecom, Defense,

Medical and more, Kokam will continue its endeavors in developing innovative,

high-tech battery solutions.

For a better future, Kokam shares the global vision of sustainable growth and

strives to create an eco friendly society. Today, Kokam seeks to materialize

this vision through the convergence of cutting-edge battery solutions and

smart software platforms.


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1.1. Kokam Battery Applications

Major Systems and Applications

ESS

Application

After proving first large-scale ESS

overseas, Kokam steadily expanded its

business in the ESS market, and

contracted with major power companies

in the US, Europe and Oceania.

Mobile

Application

In Korea, the batteries are applied as a

power source for public transportation

such as train cars and buses, expanding

the scope of business. In Europe, it is

already commercialized and is being

operated.

Aviation

Application

As the market for unmanned aerial

vehicles, drones, etc. has expanded,

Kokam's high-density energy battery has

received great attention in recent years,

and the high-density battery market is

growing rapidly

Aerospace &

Etc

Kokam is expanding its business in the

special field, where environmental

resistance, stability and safety of the

battery are key issues. Kokam saw

potential of aerospace market and

cooperated with the customers in 2016

to build a TEST BED.

Military &

Marine

Kokam's battery has the effect of

increasing operational time or radius by

maximizing the capability of domestic

and overseas mobility and launch

vehicles.

Engineering

Kokam has a 700MWh battery

manufacturing plant in Michigan in 2012,

and plans to build more battery plants in

Europe by 2020.


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1.2. Kokam Battery Characteristics

1. Advantage of Cell

Kokam manufactures NMC (Nickel manganese cobalt) cell based ESS for most projects. The high energy

density of the NMC cells has a compact design with fewer cells and equipment, as well as ensuring the

required power output. Considering the inherent cost competitiveness of the NMC cells, the NMC based ESS

solution is expected to be satisfactory in terms of pricing. Based on the length of experience and the amount

of references, it is clear that Kokam’s NMC based ESS will deliver and fulfill the technical requirements and

expectations over any other battery chemistry in the market today. The image below shows the characteristics

of two main cells Kokam provided for projects so far.

Cell Chemistry

The large pouch NMC cell has been in Kokam production for approximately 15 years with a manufacturing

process that is both automated and flexible to ensure the highest level of consistency and reliability. The

technology’s exceptional cycle life and high discharge rate capability are attributed to Kokam’s patented cell

construction design, called the Z-fold design. The cell’s parallel pairs of electrodes have very low internal

resistance, contrasted to other competing designs.

Competitiveness of Kokam Battery

A key factor in maintaining the optimum performance of the ESS is to keep the battery cell maintained within

the designed temperature range. The large surface area and thin cross section of Kokam’s large polymerized


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aluminum pouch construction allows much more efficient thermal transfer than cylindrical or thick, plastic

coated prismatic cells.

Heat dissipation on cell level

The images above shows the additional surface area and much shorter distance that heat has to travel to exit

the Kokam cells, contrasted to a pouch or competitor’s cell. It shows more than 250% increase of the heat

exchange surface area. The temperature of the competing cell is clearly higher than the Kokam cell, lower

heating characteristic allows for more vigorous operations and longer life.

High Efficiency

Due to the low internal resistance and optimal design for minimizing the loss, Kokam’s Lithium polymer battery

has achieved extremely high efficiency rates (>96.5%) @ 0.5C-rate discharge/charge). The high efficiency of

Kokam’s cells reduces the total operating cost in a battery system.

Round Trip Efficiency of NMC cells

High Power


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• Cell: 12C-rate Instant Discharge Possible

• Rack: 10P-rate Instant Discharge and

8P-rate Continuous Discharge

Internal resistance

Kokam’s high power cell has superior lower internal resistance feature. As shown on the graph (left), output

power has improved (in Red) because the internal resistance is lowered about 0.2mΩ overall. As a result,

Lower inner resistance enables the battery to discharge 4C-rate (Continuous Charge), 8C-rate (Continuous

Discharge) and 15C-rate (Instant discharge.)

Kokam’s high power cell has superior lower internal resistance feature. As shown on the graph (left), output

power has improved (in Red) because the internal resistance is lowered about 0.2mΩ overall. As a result,

Lower inner resistance enables the battery to discharge 4C-rate (Continuous Charge), 8C-rate (Continuous

Discharge) and 15C-rate (Instant discharge.)

Kokam’s superior pouch design includes a safety mechanism called tab fusing. The tab acts as a fuse and

disconnects the cell from the load within 3 seconds in the short-circuit event.

Tab Disconnected from the Cell


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1.3. Cell Certifications

Kokam’s commitment to safety has been recognized through various certifications such as UL, UN, CE, S-

Mark, SBA, KBIA, ISO, AS/NZS, and OHSAS. Note that the certification differs depending on different types of

cells. Kokam’s reliability and safety has been thoroughly vetted and evidenced by the wide acceptance of our

battery systems in various defense applications.

UL Certifications

ISO 9001 : 2009 ISO 14001 : 2009 Product Liability

Insurance AS/NZS ISO 9001-2008

AS/NZS 4801-2001 AS/NZS ISO14001-2004 OHSAS 18001-2007


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1.4. ESS/UPS References

Between 2011~2012, Kokam became the first Korean battery manufacturer to deploy a 1MWh utility size

BESS to the U.S. From that day on, Kokam has grown to be a major player within the energy storage market,

with an accumulated field record of over 184MW. These storage systems are being utilized for a variety of

applications (frequency regulation, load sharing, peak shaving and integration with renewable energy sources)

today in multiple parts of the world.

Kokam’s ESS/UPS references *Refer to the appendix for images of installed ESS/UPS

Customer / Project Name System Capacity Installation Site Installation Status

KEPCO Frequency Regulation 36MW / 13MWh Korea 2016 / 4Q Deployed

Australian Utility Spinning Reserve 30MW / 11MWh Australia 2017 / 3Q Deployed



KEPCO Frequency Regulation 16MW / 5.4MWh Korea 2014 / 4Q Deployed

Data Center UPS 15MW / 2.4MWh USA 2015 / 3Q Deployed

Germany Utility Project 5MW / 4MWh Germany 2015 / 4Q Deployed

NASA Data Center UPS 3MW / 472kWh Australia 2015 / 4Q Deployed

KEPCO Distributed ESS 2MW / 4MWh Korea 2017/ 2Q Deployed

PowerCor 2MW / 2.2MWh Australia 2015 / 3Q Deployed

KORAIL 2MW / 1MWh Korea 2013 / 4Q Deployed

Garden Island Micro Grid Project 2MW / 0.5MWh Australia 2018 / 1Q Commissioning

KEPCO Distributed ESS 1MW / 2.6MWh Korea 2017 / 2Q Deployed

SDG&E 1MW / 2.3MWh USA 2015 / 1Q Deployed

Smart Grid Market Program 1MW / 1.5MWh Korea 2013 / 4Q Deployed

Community Energy Storage 1MWh USA 2012 / 4Q Deployed

Detroit Edison (DTE) CES 1MWh USA 2013 / 1Q Deployed

Canada University 1MWh Canada 2013 / 1Q Deployed

KCP&L Smart Grid 1MW / 1MWh USA 2012 / 2Q Deployed

KETEP 1MW / 1MWh ESS 1MW / 1MWh Korea 2014 / 1Q Deployed

Duke Energy Marshall ESS 1MW / 750kWh USA 2012 / 1Q Deployed

KERI 250kW / 405kWh Korea 2013 / 4Q Deployed

Toronto Hydro Utility Energy Storage 250kW / 250kWh Canada 2013 / 1Q Deployed

Brazil SMS-250 Project 250kW / 111kWh Brazil 2017 / 4Q Deployed

ESS Project [U.S. Military] 200kWh USA 2011 / 4Q Deployed

Japan renewable energy 180kWh Japan 2012 / 1Q Deployed

TransGrid Australia 100kW / 435kWh Australia 2014 / 1Q Deployed

Germany Utility 400kWh 100kW / 400kWh Germany 2013 / 4Q Deployed

SDG&E Del Lago Academy 100kW / 210kWh USA 2013 / 1Q Deployed

San Diego Zoo project (SDG&E) 100kW / 100kWh USA 2013 / 1Q Deployed

Korea Smart Grid 100kW / 75kWh Korea 2011 / 4Q Deployed

ETI Project in California 30kWh USA 2012 / 2Q Deployed


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1.5. Terminology

Terminology and Definitions

No. Terminology Definitions

1 Bank A unit which contains a certain number of racks connected in parallel, and performs as a single body

2 BMS Battery Management System: responsible for monitoring, controlling and ensuring the safe operation of the battery energy storage system

3 BESS Battery Energy Storage System

4 BPU Battery Protection Unit

5 Cell An elementary unit storing electro-chemical energy

6 Continuous Operation

Battery is either charging or discharging at all time without rest in between

7 C-rate Current rate

8 DoD Depth of Discharge

9 KCE-H KCE-H is an acronym for Kokam Commercial Energy Storage System – High Power

10 KRI-H KRI-H is an acronym for Kokam Rack – Indoor – High Power

11 KBM-H KBM-H is an acronym for Kokam Battery Module – High Power

12 Master BMS A System level BMS

13 Module Physical unit that contains certain number of connected cells or unit cells

14 Module BMS A Module level BMS

15 NMC Nickel Manganese Cobalt Oxide

16 LTO Lithium Titanate Oxide

17 OCV Open Circuit Voltage

18 OPV Operational Voltage

19 P-rate Power rate

20 Rack A physical unit that integrates numerous battery modules – either in series or parallel - within an enclosure.

21 Rack BMS A Rack level BMS

22 Rated Capacity The rated capacity refers to the total amount of usable capacity, taking into consideration the operation conditions.

23 SLPB Superior Lithium Polymer Battery

24 System Total battery system that contains a certain number of racks or banks

25 Total Embedded

Capacity The total embedded capacity is the total amount of stored capacity without considering the operational conditions

26 Unit Cell Two or more cells connected in parallel that behaves as one cell electrically


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2. Battery System for ESS/UPS

2.1. Kokam Features

ㅍ

Space efficient - can fit in most installation

locations

Price competitive – Kokam Lithium Ion

battery is up to 20% cheaper in TCO than

lead acid

Over 95% DC-DC roundtrip efficiency

Long cycle life allows for years of continuous

use

Integrated HVAC System provides the

optimal operating conditions for batteries

Anti-heat generating technology and efficient

heat management technology

Multiple layers of safety switches, fuses, and

contactors from cell level to container level

Redundant fire suppression system and anti-

propagation design

Modular design allows for easy maintenance

and installation

Removes complications related to having

many component parts

Convenience of maintenance and monitoring

System BMS provides a single window of

monitoring for an entire battery system

Can expand to cater anywhere from kWh to

MWh demands

Supports various voltage levels for virtually

all PCS models

BMS communicates via TCP protocol


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2.2. Battery Specification

2.2.1. Cell

Kokam is proposing the most popular NMC (Nickel manganese cobalt) cell based ESS/UPS for this project.

The high energy density of the NMC cells can actualize a compact design with fewer cells and equipment, as

well as ensuring the required power output. Considering the inherent cost competitiveness of the NMC cells,

the NMC based ESS/UPS solution is expected to be satisfactory in terms of pricing. Based on the length of

experience and the amount of references, it is clear that Kokam’s NMC based ESS/UPS will deliver and fulfill

the technical requirements and expectations over any other battery chemistry in the market today.

Model Description

SLPB The Superior Lithium Polymer Battery (SLPB) 75Ah Ultra High Power cell

Cell Image1

Description Value Remark

Rated Capacity ≥75Ah SLPB130255255H

Weight 1.79±0.02kg Tab weight included

Dimension

Width 266±2mm Unfolded

Height 263±2mm Tab excluded

Thickness 13.2±0.3mm At OCV 2.2 ±0.1V

1 Images are for illustrative purposes only, actual product subject to change


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2.2.2. Module

The ingenious engineering and design of Kokam’s modules fully realizes the powerful potential of Kokam’s

Superior Lithium Polymer Batteries. The module consists of a number of unit-cells connected in series.

Kokam’s module design features unit-cell cartridge construction that enables convenient maintenance. The

unit-cells can be easily disassembled for repair, and this compact design results in a smaller footprint for the

overall system. The modules are also designed with vent holes to allow efficient air circulation for cooling,

enabling operation of up to 4 C-rate discharge. Each module is also equipped with a module BMS to monitor

battery health and status at the cell level. Kokam’s High Power Module utilizes an active cooling method via

highly efficient heat dissipation technology (installation of air cooling fans and ventilation system) on every

module to maintain optimal operation conditions from excessive environmental heat or heat generated from

high power usage. Via active cooling, the system can continue its operation while maximizing the life of the

battery.

Model Description

KBM255-H 1P20S Kokam High Power Battery Module (KBM) 255

Module Images1

Description Value Remark

Cell 75Ah

Module Configuration 1P20S 1 Parallel – 20 Series

connected (Total 20 cells)

Total Installed Capacity 5.5 kWh

Weight Approx. 50kg



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2.2.3. Rack (3-pole)

The design of the Kokam racks enables operation even in extreme conditions. They are well-suited for

demanding applications of UPS/ESS. Kokam racks include 5 levels of safety protection system; fuse,

contactor, disconnector, emergency stop switch, and enclosure with fire suppression system. Multiple

emergency safety procedures are augmented to enhance safety from almost all emergency situations. Robust

rack enclosure is equipped with redundant fire suppression system as well as designed to fulfill anti-

propagation requirement that is specified in multiple international standards to ensure protection against fire

spreading.

Model Description

KRI-H Kokam Rack Indoor(KRI-H) 1

Description Specification Remarks

Model Number KRI-P-100S+100S 3-pole, Indoor rack

Total Installed Capacity 111 kWh

Total Installed Modules 20 Modules

Dimensions 2340 x 590 x 2050 (W x D x H, mm, Preliminary)

Weight < 4000 kg Preliminary

Ambient Temperature 18oC to 28oC During stand-by

Fire Suppression FP-80S

Auxiliary Power 220 VAC Control Power

1 Images are for illustrative purposes only, actual product subject to change.


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• KRI-P-100S+100S(3-pole) Rack Technical Specification

Note:

1. “Continuous” means a single discharge from standby SOC down to the limiting minimum SOC

corresponding to the discharge power.

2. Battery degradation may shorten the discharge duration above due to the capacity fade and the

increased internal resistance of the battery cell.

Tech Terms Unit Cell Rack Remark

Ah capacity Ah 75 75 = 1.0C-rate

Energy,nominal kWh 111 = 1.0P-rate = Rated Power

Rack Energy,[email protected] kWh 101 Charge : CP-CV(@4.12V,0.05C) Discharge : CP(@3.20V)

Voltage,nominal V 3.70 740.0 3-pole connection

Voltage,highest(float,max)_in_operation V 4.10 820.0 3-pole connection

Voltage,lowest_in_operation V 3.20 640.0 3-pole connection

SoC100% V 4.090 818.0 Float Voltage

SoC95% V 4.048 809.6

SoC90% V 3.998 799.6

SoC15% V 3.565 713.0

SoC10% V 3.531 706.2

SoC0% V 3.462 692.4

Discharge P-rate,max 10.0

Discharge P-rate,max, Power kW 1110

Discharge P-rate,max, Duration sec <60 within SoC100~35%

Discharge P-rate,continuous 8.0 P-rate, tentative

Discharge P-rate,conti, Power kW 888

Discharge P-rate,conti, Duration sec <300 within SoC100~25%

Discharge P-rate,continuous 1.0

Discharge P-rate,conti, Power kW 111

Discharge P-rate,conti, Duration sec ~54min within SoC100~0%

Charge P-rate,max 2.0 P-rate, tentative

Charge P-rate,max, Power kW 222

Charge P-rate,max, Duration sec <240 within SoC15~75%

Charge P-rate,continuous 0.5 P-rate, tentative

Charge P-rate,conti, Power kW 55.5

Charge P-rate,conti, Duration sec - within SoC0~95%

Charge P-rate,continuous 0.2 P-rate, tentative

Charge P-rate,conti, Power kW 22.2

Charge P-rate,conti, Duration sec - within SoC0~100%


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2.2.4. System

Kokam Rack Indoor System (KRIS) is utilized for various applications such as peak shaving, frequency

regulation, renewable energy integration, Micro-grids and UPS. Due to the high energy and power density of

Kokam’s SLPB, the KRIS can store more energy in a given area than any of our competitors.

Model Description

KRI-H KRIS-H 100S+100S 1P

System Image1

Kokam Rack Indoor System Features

• Convenient access to control circuit / Easy maintenance

• Smart Battery Management System prevents accidental failure due to misuse

• Scalable and modular design

• Interchangeable and robust standard battery modules

• Factory programmable thresholds for application specific settings(BMS)

• State-of-the-art fire detection and suppression system



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• Runtime Analysis @SOL for Decision of Rack Configuration

Runtime Analysis

UPS 500kVA 100S+100S 1P

Nominal Energy (kWh)

111

UPS Eff. 96% P-rate Duration

(min)

PF=0.9 4.25 15*

* After 15 years, runtime duration is estimated more than 10 minutes.

• KRIS-P-100S+100S 1P Battery System for 500kVA-10min, PF0.9

Tech Terms Specification Remarks

System Configuration 100S+100S * 1 set 3-pole connection

Total Nominal Capacity 111 kWh Installed Capacity, SOL

Total Usable Energy 66.6 kWh @ AC terminal, at minimum

after 15 years

Rated Discharging Power 400 kW (500kVA, PF0.9) >15 minutes, @ AC terminal, UPS

output, SOL

Maximum Discharging Power 1110 kW <60 sec, @ DC terminal, 10P-rate

Maximum Charging Power 222 kW @ DC terminal, 2P-rate

Rated Charging Power 55 kW @ DC terminal, 0.5P-rate

Nominal Voltage 740 VDC 3-pole connection

Max. Operating Voltage 820 VDC 3-pole connection

Min. Operating Voltage 640 VDC 3-pole connection

Float Voltage 818 VDC SOC 100%

Round Trip Efficiency >96% @1.0P-rate cycle, SOL

Total Dimension 2340 x 590 x 2050 W x D x H (mm, Preliminary)

Total Weight 4,000 kg Preliminary


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2.3. Battery Management System

Every Kokam battery system includes a battery management system (BMS) which serves three critical

functions of the battery system; cell balancing, safety monitoring, and operation control. BMS balances the

cells via passive balancing to maximize capacity and extend cycle life. By monitoring voltage and temperature

at the cell level, there is no oversight of safety as the smallest unit of battery is kept within acceptable

operating conditions. The monitoring software communicates interactively with the user and power system

controllers to provide the available power. In the rare case where cells are subjected to unsafe operating

conditions, there are multiple measures that BMS can take to remove the battery system from the circuit and

protect it from any additional damages. Kokam has extensive experience in the energy storage market to

properly design and implement solutions that guarantees proper hazard analysis and the effective, safe

operation of advanced batteries.

Each Kokam battery module contains a module BMS, which gathers cell-unit voltage and temperature and

transmits them to the rack BMS. Rack BMS gathers the data and analyzes the status of the battery.

Bank/System BMS analyzes the data from the racks to provide real time information on the remaining energy

(state of charge), predictive maintenance/replacement cycles (state of health), and available power of the

batteries. The information is presented to the user via Human Machine Interface (HMI) or PC based software

and to the controller for each of the associated load and power supply, such as a PCS, inverter or charger.

2.3.1. Module BMS

Model Description

• Monitors battery pack voltage and temperature

• Passive Type Cell equalization & Balancing

• CAN communication up to Rack BMS

• Power shut down function

※The image on the left is for reference purposes. The actual product may be different.

Installed into an integrated module BMS housing of the module, the module BMS is at the lowest of the BMS

hierarchy. At the module level, which is the smallest unit system, each and every cell’s voltage and

temperature are measured via module BMS and the module BMS uses these information to calculate the

module voltage. Module BMS also performs the cell equalization and balancing by parameters provided by

the rack BMS (or other upper device).


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2.3.2. Rack BMS

Model Description

• Collects information from Module BMS through CAN protocol

• Charge/discharge Current measurement

• Cell High / Low Voltage protection & alarm

• Over Current protection & alarm

• High Temperature alarm & protection

• Automatic shutdown & wakeup (optional)

• Magnetic contactor ON/OFF control

• Single Rack SOC calculation

※The image on the left is for reference purposes. The actual product may be different

All of the information gathered in module level mentioned above in “section 3.6.1 Module BMS” are sent to the

rack BMS. The rack BMS takes this information, then calculates and lets the customer know the battery rack’s

current status including SOC, SOH, power, voltage (rack, min/max cell), and charge / discharge status of the

rack. Furthermore, the rack BMS notifies the user of the fault / alert status including high/low temperature,

voltage, current and communication error. Thus in a rare case when the system goes offline due to a problem,

one can easily identify where the problem occurred and fix the problem.

2.3.3. BMS Monitoring Software

Model Description

• Window-Based PC software

• Monitor various battery data

• Monitor battery faults and alarms

• Modify BMS settings

• Change BMS parameters

• Data logging

※The image on the left is for reference purposes. The actual product may be different

The BMS Monitoring Software is provided with every product equipped with a rack BMS. The software allows

the users to monitor and manage the battery through the rack BMS, without any other software/hardware. By

most design, the BMS communicates all critical information and receives commands from an upper device,

which is usually the inverter. The BMS monitoring software supplements this design by providing another

method of connection to the battery, in case of upper device failure or other faults. This program is

compatible with most Windows-based PC and provides functions to monitor and manage the BMS

independently. After establishing a successful connection with the rack BMS, the software can monitor status

of the battery, read and log individual module and cell level data, assign BMS ID/IP address, modify the BMS

settings, change the BMS parameters, and more. The software is used mostly during commissioning /

acceptance tests and troubleshooting.


23

3. Testing Program

3.1. FAT Type Test

3.1.1. Type Test (or Factory Test)

Item No. Test

Storage Battery

1 Over Voltage Protection

2 Under Voltage Protection

3 Over Temperature Protection

4 Low Temperature Protection

5 Over Current Protection

6 Voltage Imbalance Protection

3.1.2. Individual Test List

Item No. Test

Storage Battery

1 Over Voltage Protection

2 Under Voltage Protection

3 Over Temperature Protection

4 Low Temperature Protection

5 Over Current Protection

6 Voltage Imbalance Protection

3.1.3. Site Test List (Not included in the scope of offer)

Item No. Test

Storage Battery

1 Energy Capacity Test

2 Round Trip Efficiency Test

3 Response Time Test

4 Insulation Test


24

4. Maintenance and Training

4.1. Maintenance

4.1.1. Storage Batteries

Once the design review has been approved, the specific maintenance manual will be provided prior to

commissioning.

4.1.1.1.Preventive Maintenance

The preventive maintenance is executed to prevent system error or failure during operation. The operator

must perform a monthly to yearly based maintenance for preventive measures.

The operator must regularly check the equipment failure, damage, loss of parts, etc., during the preventive

maintenance to maintain the equipment for systematic management and perform preventive action when

necessary.

Inspection

Inspection shall be performed on all parts included in the preventive maintenance checklist by examining the

condition, proper assembly, assured safety, or abrasion of each part.

No. Inspection Item Description

1 Status Visually inspect any damaged items that are expired of usage or safety

2 Proper Assembly & Installation Visually inspect incorrectly assembled or installed parts

3 Safety Visually inspect any loose parts and tighten them wrench or driver

4 Busbar, Screw, Bolt

Check any loose, worn out, and damaged parts Check for rust on exposed metal parts, bolts, screw heads and nuts Tighten if any of these are loosened

5 Connection, Wiring Tighten the loosened connections and check if the insulator and connection of the old wires are damaged

6 Cable Connector and Switch Check and remove any foreign substance on the cable connectors and switches.


25

List of Preventive Maintenance

No. Item Category Maintenance Period

Monthly Yearly

1 BPU

Rack MCCB

●

Main Contactor

●

Rack Fuse ●

2 Rack Rack Fan ●

System Ready Lamp ●

3 DCP

Isolation Switch

●

Switch Disconnector ● ●

ELD(Earth Leakage Detector)

●

Fuse ●

Voltage meter ●

4 Container Emergency Function

●

5

Fires Suppression Smoke Detector & Alarm

●

Thermal Detector & Alarm

●

6 HVAC Refer to HVAC manual

7 Special Tools Insulated Gloves & Tool set

●

4.1.1.1.1. Corrective Maintenance

The corrective maintenance illustrates the repair procedure of the defective items and the tools necessary for

the corrective maintenance.

The corrective maintenance guide is the list of procedures that the operator must follow in order to inspect,

test, replace, and repair components of the Battery System when they are in need of remedy. The corrective

maintenance includes visual inspection and self-diagnosis of all components along with the means to replace

them.

4.1.2. Objective

• Avoid potential risks and accidents in advance

• Maintain an optimum operating condition

• Ensure the performance

4.1.3. Organization

Maintenance organization has a unified quality assurance team. It allows for fast problem solving as well as

optimal operation.

Team Major Contents

QA

Operator Support Reception of customer complaints

Preventive Maintenance Performing preventive maintenance

Corrective Maintenance Performing corrective maintenance


26

4.2. Training

4.2.1. Contents

Training contents can be customized based on request.

System Course Contents

Sto

rag

e B

atte

ry

• Principles and overview of the Battery System

• Understanding of Hardware

• Understanding of Software

• Understanding of Electrical Characteristics

• Operation Procedure

• Termination

• Diagnostic check of the battery status

• Recording data and analysis

• Emergency plan

• Signals and Parameters

• Maintenance (Preventive and Corrective)


27

5. Appendix (Detailed References)

5.1. Spinning Reserve & Frequency Regulation References

Kokam undertakes some of the largest ESS turnkey Electrification projects in Australia. We are currently

delivering 30MW/11MWh ESS, which features Kokam’s Ultra-High Power Nickel Manganese Cobalt(NMC)

battery technology.

Location

Application

Capacity/Power

Installation date

Australia

Spinning

Reserve,

FR, UPS

30MW/11MWh

2017/2Q

Another project features a combination of three unique Kokam lithium ion battery technologies-the UHP NMC

battery technology and LTO battery technology.

Kokam has deployed for KEPCO (Korean Electric Power Corporation) a total of 92MW/33MWh ESS system

and 16 MW (6 MWh) system. Together these systems currently provide KEPCO with 92MW of energy storage

capacity for frequency regulation. Kokam has supplied KEPCO with its Ultra High Power NMC and LTO

battery technologies. Work on the project began in 2014, and was completed in 2016.

http://www.renewableenergyfocus.com/view/43850/korean-energy-storage-project-features-largest-lithium-nmc-system-deployed-for-electricity-grid-frequency-regulation/


28

Location

Application

Capacity/Power

Installation date

Korea

Spinning

Reserve, FR

36MW/13MWh

2016

Location

Application

Capacity/Power

Installation date

Korea

Spinning

Reserve, FR

24MW/9MWh

2015


29

Location

Application

Capacity/Power

Installation date

Korea

Spinning

Reserve, FR

16MW/6MWh

2015

Location

Application

Capacity/Power

Installation date

Korea

Spinning

Reserve,

UPS, FR

16MW/5MWh

2014

High Power ESS Projects


30

Location

Application

Capacity/Power

Installation date

Texas, USA

Data Center

UPS

15MW/2.4MWh

2015

Location

Application

Capacity/Power

Installation date

Canberra, Australia

UPS, FR

3MW/472kWh

2015


31

5.2. Additional Reference List for ESS/PCS

Germany Utility Project

Location

Application

Capacity/Power

Germany

Frequency Regulation

5MW /4MWh

6.

KEPCO Distributed ESS

Location

Application

Capacity/Power

JungEup, Korea

Peak Shaving

2MW/4MWh

7.

Powercor Project

Location

Application

Capacity/Power

Melbourne, Australia

Peak Shaving

2MW/2.2MWh

Korea Railway Project

Location

Application

Capacity/Power

Installation Date

Korea

Spinning Reserve, Peak Shaving

2MW/1MWh

2013 / 4Q

AES Frequency Regulation Project

Location

Application

Capacity/Power

Installation date

Indiana , USA

Frequency Regulation, Spinning Reserve

2,000kW/500kWh

2008 ~ 2009

Vector Home Energy Storage System

Location

Application

Capacity/Power

New Zealand

Distributed ESS, Peak Shaving,

Renewable Energy Integration(PV)

1.8MW/3.45MWh


32

KEPCO Island Off Grid ESS

Location

Application

Capacity/Power

Installation Date

Gasa Island, Korea

Renewable Integration(Wind+PV)

Off Grid power supply

1.25MW/3.2MWh

2014 / 2Q

KEPCO Outdoor ESS

Location

Application

Capacity/Power

Installation Date

Yeongju, Korea

Distribution Deferral

1MW/2.6MWh

2016 / 4Q

SDG&E Renewable Energy Integration Project

Location

Application

Capacity/Power

Installation Date

San Diego, USA

Renewable Energy Integration(PV),

Peak Shaving

1MW/2.3MWh

2015 / 1Q

Smart Grid Demonstration Project

Location

Application

Capacity/Power

Installation Date

Korea

Peak Shaving

1MW/1.5MWh

2011 / 4Q

KCP&L Smart Grid Demonstration Project

Location

Application

Capacity/Power

Installation Date

Missouri, USA

Renewable Energy Integration,

1MW/1.1MWh

2012 / 2Q


33

KETEP 1MW/1MWh Industrial ESS Project

Location

Application

Capacity/Power

Installation Date

Korea

Spinning Reserve, Renewable Integration

Demand Response, Peak Shaving

1MW/1.1MWh

Manufacturing

Hyundai Heavy Industry Solar Panel Manufacturing Plant

Location

Application

Capacity/Power

Korea

Renewable Integration


1MW/1MWh

AEP Community Energy Storage

Location

Application

Capacity/Power

Ohio, USA

Distributed Energy Storage System,

Voltage Support, Peak Shaving

1,000kWh/1,000kW

Duke Energy Marshall Energy Storage Project

Location

Application

Capacity/Power

Installation date

North Carolina, USA


Peak Shaving, PCS:S&C

800kWh/1,000kW

2012 / 1Q

Detroit Edison(DTE) Community Energy Storage Project

Location

Application

Capacity/Power

Installation Date

Detroit, USA



1,000kWh/500kW

2011 / 2Q ~ 2012/4Q


34

University British of Colombia ESS

Location

Application

Capacity/Power

Installation Date

Vancouver, Canada

Peak Shaving, UPS

1,000kWh/200kW

2013 / 1Q

University of Queensland ESS

Location

Application

Capacity/Power

Vancouver, Canada

PV Integrated, Grid Support

800kWh/600kW

Canada Utility Energy Storage (Toronto Hydro)

Location

Application

Capacity/Power

Installation Date

Toronto , Canada



500kWh/250kW

2013 / 1Q

Transgrid Project

Location

Application

Capacity/Power

Australia

Peak Shaving, Load Levelling,

Grid ESS

435kWh/100kW

Smart Grid Market Penetration Program

Location

Application

Capacity/Power

Installation date

Changwon , Korea


405kWh/250kW

2013 / 4Q

ENBW Utility 400kWh ESS Project

Location

Application

Capacity/Power

Installation date

Germany

Peak Shaving

400kWh/400kW

2013 / 4Q


35

Seoul National Park ESS Project

Location

Application

Capacity/Power

GwaCheon , Korea

Peak Shaving

310kWh/250kW

2013 / 4Q

HECO Frequency Regulation Project

Location

Application

Capacity/Power

Installation date

Hawaii , USA

Frequency Regulation, Spinning Reserve

250kWh/1,200kW

2011

Solver Project

Location

Application

Capacity/Power

Installation date

Germany

Peak Shaving

230kWh/250kW

2013 / 4Q

8.

Google Datacenter

Location

Application

Capacity/Power

Google campus, USA

Peak Shaving

100kW / 222kWh

San Diego Del Lago High School ESS

Location

Application

Capacity/Power

Installation date

San Diego , USA


Peak Shaving

210kWh/100kW

2014 / 1Q

KORAIL ESS Demonstration

Location

Application

Capacity/Power

Installation date

Korea

Peak Shaving

200kWh/200kW

2012


36

San Diego Zoo project

Location

Application

Capacity/Power

Installation date

San Diego , USA

Renewable Energy Integration,

EV Charging Station, Peak Shaving

100kWh/100kW

2013 / 1Q

SK C&C Ganagwon-do Demonstration Project

Location

Application

Capacity/Power

Installation date

West Ansung, Korea

Korea


Peak Shaving

100kWh/140kW

Weinberg Project

Location

Application

Capacity/Power

Installation date

Germany

Peak Shaving

100kWh/100kW

2014

Infigen Energy Demonstration Project

Location

Application

Capacity/Power

Installation date

Australia


70kWh/100kW

2014 / 1Q

*Separate attachment with an exhaustive reference list can be provided upon request

kokam technical proposal - elithion.comelithion.com/pdf/kokam technical proposal for...

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