The Australian Battery Guide

ESC 5000.2016

The Australian Battery Guide

Energy Storage Council (ESC)

The Australian Battery Guide Guide for Energy Storage Systems (sales, design, installation and stewardship) Revision 0.9 May 2016

Document Number: 003 Copyright and published by Energy Storage Council, ACT, Australia 2016 Author: Peter Cockburn

Release Notes: Revision 0.9 - High level overview of The Australian Battery Guide.

The ESC have released this revision to actively seek feedback and comment for a rapid release of Revision 1.0.

PREFACE This guide, prepared by the Australian Energy Storage Council (ESC), is an easy to understand framework designed to provide guidance to the energy storage industry and consumers in the interim while formal Australian Standards and being developed for the sector.

Industry leading companies are committed to the highest levels of safety and performance. Together with consumers and other stakeholders the industry is actively involved in creating ‘worlds best practice’ when it comes to producing, selling, using and disposing of energy storage products.

Together we have a shared responsibility to mange energy storage products and materials to reduce their impact on the environment and manage any risks they may pose to human health and safety.

Over the last few years battery technology has undergone rapid change with a range of new chemistries being developed. It is no longer practical to dedicate a standard to a single battery chemistry. A new approach is required to accommodate the wide variety of battery chemistry under a single design and installation guide.

Lithium-ion based batteries are quickly gaining market share in this sector. As such we have carefully considered the appropriate management required for this class of batteries in this guide. That said, this guide is designed to grow and be enhanced, augmented and updated to be applicable to all emerging ESS technologies.

This approach to provide ‘just in time’ expert advice is focused in the first instance at identifying areas where the current understanding is lacking and additional work is required to maintain system safety.

Feedback and comment on this guide is always welcome.

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CONTENTS 1

SCOPE & GENERAL .................................................................................................. 6 1.1 SCOPE................................................................................................................ 6 1.2 REFERENCED DOCUMENTS ............................................................................ 6 1.3 DEFINITIONS ...................................................................................................... 7 1.4 ESS Installation Types ........................................................................................ 8 1.4.1 UPS ............................................................................................................. 8 1.4.2 GRID HYBRID ............................................................................................. 8 1.4.3 OFF-GRID ................................................................................................... 9 1.4.4 Other ESS Functions................................................................................. 10 1.4.5 Renewable Output Variation Mitigation .................................................... 13 2 Energy & Power Assessment .................................................................................. 13 3 Specifying — Energy Storage System Performance............................................... 15 4 System Configuration .............................................................................................. 16 4.1 UPS .................................................................................................................. 16 4.2 ESS T Configuration ......................................................................................... 19 4.3 ESS Critical Loads ............................................................................................ 21 4.4 ESS Off Grid (Stand Alone Power System) ...................................................... 22 5 Selection of Battery Technology ............................................................................. 23 5.1 General ............................................................................................................. 23 5.2 Safety Data Sheet (SDS) ................................................................................... 23 5.2.1 SDS - Key Information Areas .................................................................... 24 6 Hazards associated with batteries .......................................................................... 25 7 Battery Classification............................................................................................... 25 7.1 Category 1 - Un-defined ................................................................................... 26 7.2 Category 2 - Explosive Atmospheres ............................................................... 26 7.3 Category 3 - High Temperature ........................................................................ 26 7.4 Category 4 - Toxic Atmospheres ..................................................................... 26 7.5 Category 5 - Hazardous Spills.......................................................................... 26 7.6 Category 6 - Corrosive ..................................................................................... 26 7.7 Category 7 - Inert ............................................................................................. 27 8 Battery Accommodation ......................................................................................... 27 9 Battery Enclosure Requirements ............................................................................. 27 9.1 Enclosure Categories ....................................................................................... 28 9.1.1 Category 1 - Un-defined ........................................................................... 28 9.1.2 Category 2 - Explosive Atmospheres ....................................................... 28 9.1.3 Category 3 - High Temperature ................................................................ 28 9.1.4 Category 4 - Toxic Atmospheres .............................................................. 28 9.1.5 Category 5 - Hazardous Spills .................................................................. 28 9.1.6 Category 6 - Corrosive .............................................................................. 28 9.1.7 Category 7 - Inert ...................................................................................... 28 9.2 Enclosure - Egress and Access ........................................................................ 28 10 Battery Room Requirements ................................................................................ 29 11 Installation ............................................................................................................ 29 12 Labelling ............................................................................................................... 30 12.1 FIRE EMERGENCY SERVICES INFORMATION ........................................... 30 12.1.1 Warning sign Battery ............................................................................. 31 12.1.2 ESS Sign Overview - Example .............................................................. 31 13 Documentation ..................................................................................................... 32 14 Commissioning..................................................................................................... 32 15 Maintenance ......................................................................................................... 33 16 Stewardship ......................................................................................................... 33 17 Australian Standards ............................................................................................ 34

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FIGURES FIGURES Figure Figure11- -ESS ESSSCOPE SCOPE...................................................................................................... ......................................................................................................66 FIGURES Figure Figure22- -UPS UPSESS ESSSYSTEM SYSTEM............................................................................................ ............................................................................................88

Figure 1 - ESS SCOPE ...................................................................................................... 6 Figure Figure33- -AC ACGRID GRIDHYBRID HYBRIDESS ESSBLOCK BLOCKDIAGRAM DIAGRAM....................................................... .......................................................88 Figure 2 - UPS ESS SYSTEM ............................................................................................ 8 Figure Figure44- -DC DCGRID GRIDHYBRID HYBRIDESS ESSBLOCK BLOCKDIAGRAM DIAGRAM....................................................... .......................................................99 Figure 3 - AC GRID HYBRID ESS BLOCK DIAGRAM ....................................................... 8 Figure Figure55- -OFF-GRID OFF-GRIDESS ESSBLOCK BLOCKDIAGRAM DIAGRAM................................................................... ...................................................................99 Figure 4 - DC GRID HYBRID ESS BLOCK DIAGRAM ....................................................... 9 Figure Figure66- -LOAD LOADSHIFTING SHIFTING............................................................................................. .............................................................................................10 10 Figure 5 - OFF-GRID ESS BLOCK DIAGRAM ................................................................... 9 Figure Figure77- -TARIFF TARIFFOPTIMISATION OPTIMISATION.................................................................................. ..................................................................................11 11 Figure 6 - LOAD SHIFTING ............................................................................................. 10 Figure 8 PEAK LOPPING ..............................................................................................

12 Figure 8 - PEAK LOPPING .............................................................................................. 12 Figure 7 - TARIFF OPTIMISATION .................................................................................. 11 Figure Figure99- -EXPORT EXPORTLIMITING LIMITING.......................................................................................... ..........................................................................................12 12 Figure 8 - PEAK LOPPING .............................................................................................. 12 Figure Figure10 10- -NETWORK NETWORKSUPPORT SUPPORT................................................................................... ...................................................................................13 13 Figure 9 - EXPORT LIMITING .......................................................................................... 12 Figure Figure11 11- -ENERGY ENERGYASSESSMENT ASSESSMENT............................................................................... ...............................................................................14 14 Figure 10 - NETWORK SUPPORT ................................................................................... 13 Figure Figure12 12- -ENERGY ENERGY&&POWER POWERASSESSMENT ASSESSMENT.............................................................. ..............................................................14 14 Figure 11 - ENERGY ASSESSMENT ............................................................................... 14 Figure Figure13 13- -ESS ESSSYSTEMS SYSTEMSNOT NOTEQUAL EQUAL........................................................................ ........................................................................15 15 Figure 12 - ENERGY & POWER ASSESSMENT .............................................................. 14 Figure Figure14 14- -UPS UPS(STANDBY) (STANDBY)- -LAYOUT LAYOUTEXAMPLE EXAMPLE......................................................... .........................................................17 17 Figure 13 - ESS SYSTEMS NOT EQUAL ........................................................................ 15 Figure Figure15 15- -UPS UPS(ESS), (ESS),WITH WITHRENEWABLE RENEWABLE- -LAYOUT LAYOUTEXAMPLE EXAMPLE................................. .................................18 18 Figure 14 - UPS (STANDBY) - LAYOUT EXAMPLE ......................................................... 17 Figure Figure16 16- -ESS ESSTTCONFIGURATION CONFIGURATION- -LAYOUT LAYOUTEXAMPLE EXAMPLE........................................... ...........................................19 19 Figure 15 - UPS (ESS), WITH RENEWABLE - LAYOUT EXAMPLE ................................. 18 Figure ...........................................................

Figure17 17- -ESS ESSDC DCTO TODC DC- -LAYOUT LAYOUTEXAMPLE EXAMPLE ...........................................................20 20 Figure 16 - ESS T CONFIGURATION - LAYOUT EXAMPLE ........................................... 19 Figure Figure18 18- -CRITICAL CRITICALLOADS LOADS- -LAYOUT LAYOUTEXAMPLE EXAMPLE....................................................... .......................................................21 21 Figure 17 - ESS DC TO DC - LAYOUT EXAMPLE........................................................... 20 Figure 19 ENCLOSURE REQUIREMENTS FLOW CHART ............................................

26 Figure 19 - ENCLOSURE REQUIREMENTS FLOW CHART............................................ 26 Figure 18 - CRITICAL LOADS - LAYOUT EXAMPLE ....................................................... 21 Figure Figure20 20- -BATTERY BATTERYSIGN SIGN............................................................................................. .............................................................................................31 31 Figure 19 - ENCLOSURE REQUIREMENTS FLOW CHART............................................ 26 Figure Figure21 21- -ESS ESSSIGNAGE SIGNAGEOVERVIEW OVERVIEW........................................................................... ...........................................................................32 32 Figure 20 - BATTERY SIGN ............................................................................................. 31 Figure 21 - ESS SIGNAGE OVERVIEW ........................................................................... 32

TABLES TABLES TABLES

Table Table11- -SDS SDSKEY KEYINFORMATION INFORMATIONAREAS AREAS.................................................................... ....................................................................24 24 Table 1 - SDS KEY INFORMATION AREAS .................................................................... 24

EQUATIONS EQUATIONS EQUATIONS

Equation Equation11- -TOTAL TOTALENERGY ENERGYTHROUGHPUT THROUGHPUT(MWh) (MWh)...................................................... ......................................................77 Equation 1 - TOTAL ENERGY THROUGHPUT (MWh) ...................................................... 7

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1 SCOPE & GENERAL 1.1 SCOPE This guide specifies general requirements for design and installation of all ESS, including those connected, and not connected, to a power distribution system and those that are not connected to a power distribution system.

The ESC is committed to responsible product stewardship throughout the lifecycle of these products. This includes identifying and managing the impacts of these products in their production, sale, use and disposal. There is a shared responsibility to ensure that those products or materials are managed in a way that reduces their impact, throughout their lifecycle, on the environment and on human health and safety.

This Guide applies to installations of all types of batteries with a total capacity of 240Wh or greater (example; 24V with capacity of 10Ah).

NOTE: The Australian Battery Guide will cover these areas; 1 NO Energy Storage

2 Energy Assessment (Domestic / Commercial or Industrial)

3 ESS – Performance Requirements (Grid Hybrid or Off-Grid)

4

5

6

ESS Configuration

Selection of Battery Technology

Hazards Associated with Batteries

(Grid Hybrid or Off-Grid)

( WHS aspects of ESS )

( UPS, ESS T Config, ESS Critical Loads, ESS Off-Grid)

7 Battery Classification (Determining the Battery Category (s) )

Scope, Referenced Documents and Definitions ESS PRODUCT TESTING

PRODUCT STEWARDSHIP (ESC Product WHITE LIST)

8

9

10

11

12

13

Battery Accommodation

Battery Enclosure Requirements

Battery Room Requirements

Installation

Labelling

( Categories 1 to 7 )

( Categories 1 to 7 )

( Location, Earthing, Seismic, Cabling, Electrical, Mechanical )

(Switchboard, ESS Equipment, Enclosures / Rooms, Emergency Services )

Documentation

( Cooling, Ventilation, Enclosure Requirements and Room Requirements )

( User Manual, Network Operator Diagrams )

ESS Register (ESC maintained Register of all ESS Systems Installed, for use by emergency services and regulators )

14

15

Commissioning

Maintenance

( Inter-Cell, String, Array, Protection Systems )

( User , Installer )

ESS Owner

16 STEWARDSHIP ( Product recycling at End of Life )

Figure 1 - ESS SCOPE

1.2 REFERENCED DOCUMENTS The information contained in this guide has been derived from Australian Standards, research papers from CSIRO, Worksafe Australia, Karlsruhe Institute of Technology (KIT), DNV GL and other energy storage industry participants.

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1.3 DEFINITIONS For the purpose of this guide, the definitions below apply.

1.3.1.

Energy Storage System (ESS) — combination of convertors, switches (for example multi-mode inverters) and energy storage devices (for example, batteries), constituting a power system that supports the load or for maintaining continuity of load power in case of input power failure or as the primary source of power. The energy may flow from input to output, output to input or a combination of both.

1.3.2.

Grid — the portion of the electrical distribution system that is operated by an electrical distributor.

NOTE: An alternative term for ‘grid’ is ‘electricity distribution network’.

1.3.3.

Multiple Mode Inverter (MMI) — An inverter that operates in more than one mode, for example having grid-interactive functionality when grid voltage is present and stand-alone functionality when the grid is de-energized or disconnected.

NOTES: 1 Inverters with battery storage ports are also considered multiple mode inverters.

2 As defined in IEC 62109-2, Clause 3.107.

1.3.4.

Safety Data Sheet (SDS) — previously called a Material Safety Data Sheet (MSDS), is a document that provides information on the properties of hazardous chemicals and how they affect health and safety in the workplace.

1.3.5.

Stand-alone Power System (SPS) — Systems that are not connected to the power distribution network of an electricity distributor. Stand-alone systems are supplied with power from one, or more, of a number of sources including, but not limited to, a photovoltaic array, a wind turbine generator, a micro-hydro generator or an engine generator set.

1.3.6.

Total Energy Throughput (TET) — a product of the usable energy that can be obtained from an ESS during a cycle and the number of cycles (charge/discharge) the ESS shall support, often measured in MWh. Total Energy Throughput (MWh) =

usable energy (kWh) x battery cycle life 1000

Equation 1 - TOTAL ENERGY THROUGHPUT (MWh)

NOTE: where batteries operate at varying discharge levels, the TET is the sum of the usable energy delivered over the total number of cycles achieved during its service life.

1.3.7.

Uninterruptible Power System (UPS) — combination of convertors, switches and energy storage devices (for example, batteries), constituting a power system for maintaining continuity of load power in case of input power failure. Provides a one way flow of energy from input to output.

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1.4 ESS Installation Types The ESS installation type is divided into three main categories. It should be noted at a specific site, a number of different categories of ESS may be installed. The general categories are detailed in the following list; • UPS • Grid Hybrid • Off Grid (SPS)

1.4.1 UPS The UPS ESS system is defined as having a one way energy flow from input to output.

Refer to Figure 2 for details.

UPS BLOCK DIAGRAM (STANDBY)

TRANSFER SWITCH

INPUT (GRID)

UPS BLOCK DIAGRAM (DOUBLE CONVERSION) OUTPUT

INPUT (GRID)

INVERTER

INVERTER

CHARGER

CHARGER

BATTERY BATTERY

Figure 2 - UPS ESS SYSTEM

1.4.2 GRID HYBRID The Grid Hybrid ESS system may have a bi-directional energy flow allowing energy to flow from input to output or output to input. These systems may be configured for export to the grid, limited export to the grid or not export to the grid.

Refer to Figure 3 for details on AC Grid Hybrid ESS and Figure 4 for DC Grid Hybrid ESS. GRID HYBRID BLOCK GRID HYBRID BLOCK DIAGRAM DIAGRAM (T Configuration) (Essential Load/s) INPUT

INPUT

OUTPUT

(GRID)

OVER CURRENT PROTECTION / ISOLATION

OUTPUT

(GRID) GRID Protection / disconnection

SOURCE

LOAD

MMI INVERTER

MMI INVERTER

BATTERY

BATTERY

Figure 3 - AC GRID HYBRID ESS BLOCK DIAGRAM

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GRID HYBRID BLOCK DIAGRAM (DC ESS) INPUT

OUTPUT

(DC to SOLAR INVERTER)

(DC PV MODULES)

SOURCE

LOAD

DC ESS

BATTERY

Figure 4 - DC GRID HYBRID ESS BLOCK DIAGRAM

1.4.3 OFF-GRID The Off-Grid ESS system may be configured in many different ways, in general the system will have a bi-directional energy flow on the output and when alternative generation is installed a one way energy flow on the input as most alternative generation is not designed to have energy fed into the generation source. Refer to Figure 5 for details.

OFF-GRID BLOCK DIAGRAM ALTERNATE GENERATION

OUTPUT

Protection / disconnection

SOURCE

LOAD

MMI INVERTER / Battery Charger

BATTERY

Figure 5 - OFF-GRID ESS BLOCK DIAGRAM

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1.4.4 Other ESS Functions In addition to the general ESS types, an ESS system may be used for one or a combination of the following; • Load Shifting • Tariff Optimisation • Load Support or Demand Reduction • Renewable Export Mitigation • Network Support

1.4.4.1 Load Shifting The surplus solar energy is stored and shifted to other time periods. Refer to Figure 6 for details.

LOAD SHIFTING SOLAR GENERATION

kW

ENERGY USE

SURPLUS SOLAR ENERGY STORED ENERGY

STORED ENERGY 12AM

4AM

8AM

12PM

4PM

8PM

12AM

Time Figure 6 - LOAD SHIFTING

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1.4.4.2 Tariff Optimisation The energy is stored in ESS during times of low cost energy tariff and used during times of high cost energy tariff. Refer to Figure 7 for details, the example provide uses the Victorian network tariff, other network areas may use different tariff/s and times.

TARIFF OPTIMISATION OFF-PEAK TARIFF

SHOULDER TARIFF

PEAK TARIFF

ENERGY IMPORTED ENERGY USE

kW

STORED ENERGY

12AM

4AM

8AM

12PM

4PM

8PM

12AM

Time Figure 7 - TARIFF OPTIMISATION

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1.4.4.3 Peak Lopping The peak energy used in many demand tariff supply arrangements can greatly affect the cost of energy for the entire billing / contract period. The ability of the ESS system to reduce the maximum demand on the network benefits both the network provider and the customer. Refer to Figure 8 for detailed example.

PEAK LOPPING OFF-PEAK TARIFF

STORED ENERGY

kW

OFF PEAK TARIFF

PEAK TARIFF

DEMAND TARIFF 3

ENERGY USE

ENERGY IMPORTED

DEMAND TARIFF 2

DEMAND TARIFF 1

12AM

4AM

8AM

12PM

4PM

8PM

12AM

Time Figure 8 - PEAK LOPPING

1.4.4.4 Export Limiting The export of solar energy in some network operator controlled electricity distribution networks is either limited to a set maximum or not allowed at all for new solar customers. Export limiting may vary from "ZERO EXPORT" to minimal export. The ESS system can be used to store surplus solar energy for use at different time periods.

Refer to Figure 9 for an example of an export limiting configuration.

EXPORT LIMITING SOLAR GENERATION

kW

ENERGY USE

SURPLUS SOLAR ENERGY

EXPORT LIMIT

EXPORTED ENERGY STORED ENERGY

STORED ENERGY

12AM

4AM

8AM

12PM

4PM

8PM

12AM

Time Figure 9 - EXPORT LIMITING

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1.4.4.5 Network Support The support of network capacity can take a number of different forms, this will depend of the site specific circumstances associated with the network and customer. The support may be energy, power, voltage, power factor, frequency or a combination. Refer to Figure 10 for an example of power support.

NETWORK SUPPORT NETWORK SUPPORT REQUIRED NETWORK ENERGY USE

NETWORK ENERGY EXPORTED

kW

12AM

NETWORK ENERGY IMPORTED

4AM

8AM

12PM

4PM

STORED ENERGY

8PM

12AM

Time Figure 10 - NETWORK SUPPORT

1.4.5 Renewable Output Variation Mitigation Where batteries are used to offset sudden rises or fall in renewable output (e.g. PV or wind) resulting in excessive voltage fluctuations.

2 Energy & Power Assessment The energy and power assessment for the load to be supported by the ESS should be conducted in conjunction with each other, as some ESS applications may require greater emphasis on energy or power.

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ENERGY ASSESSMENT

GRID HYBRID

DOMESTIC

OFF GRID

COMMERCIAL & INDUSTRIAL

DOMESTIC

COMMERCIAL & INDUSTRIAL

Figure 11 - ENERGY ASSESSMENT

Given that many of the ESS applications can apply equally to domestic and commercial and industrial (C&I) sites, suggestion is given to an alternate arrangement that focuses on each of the 3 installation types; grid hybrid, backup or off-grid, or the other ESS functions described above.

ENERGY & POWER ASSESSMENT

GRID HYBRID

BACKUP

OFF GRID

OTHER ESS FUNCTIONS

Figure 12 - ENERGY & POWER ASSESSMENT

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3 Specifying — Energy Storage System Performance

Figure 13 - ESS SYSTEMS NOT EQUAL

The specifying of performance parameters for an energy storage system shall be done using the following common minimum set of parameters. The common parameters allow for comparisons between system vendors quotes.

The common parameters include; The Energy storage system shall be capable of at least the following;.

• Usable Energy (kWh) • Maximum Power output (kW) over what pf range (if AC output) • If AC output, operating pf range (leading to lagging) • Battery System - life time to be minimum of 8 years • ESS Maximum Surge Load (kVA) • ESS Maximum Power output • ESS output Power, time period of 1s, 30s, 1min, 30min and continuous • Maximum Recharge Power available from source or Maximum or Minimum Recharge power allowed / required by storage device.

• Battery Total Energy Throughput (MWh) • Standby SOC for storage device • Response Time in ms.

• Storage Device self-discharge rate (usually %/month) • Energy Storage Device maximum prospective fault current and protective device capability • Energy Storage Device operating DC Voltage range (if applicable) • Energy Storage Device maximum heat dissipation during operation • Backup up Power - Yes /No • Days of Autonomy - how long will the system support the load without renewable energy input.

• Warranty on equipment • Warranty on battery (including temperature ranges) • Operating temperature range • For AC Converters, fault clearance capability and protection devices included • Standards compliance eg AS3000, AS5033, AS4777, AS5603

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4 System Configuration The ESS system configuration is defined by a number of factors; • Customers' Requirements • Manufactures Documentation and Intended use • Australian Standards & Utility Requirements Examples of possible configurations for each system type are provided in this section. It should be noted the ESS system installation and intended use follows manufactures documentation.

4.1 UPS UPS can be generally split into two categories; • Standby • Online (with optional renewable generation) The following diagrams show some of the possible methods that UPS system may be integrated into existing electrical systems.

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OVER CURRENT PROTECTION & ISOLATION AC Input

AC Output

CHANGE OVER SWITCH

BATTERY

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UPS ISOLATION SWITCH

OVER CURRENT PROTECTION

INVERTER / CHARGER

Figure 14 - UPS (STANDBY) - LAYOUT EXAMPLE

(GRID)

INPUT

GRID PROTECTION DEVICE

NOTE: These items may be integrated into one device

(STANDBY)

UPS LAYOUT EXAMPLE

M

UPS LOADS

METER (kWh)

UPS SWITCHBOARD

LOADS

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METER ISOLATOR

M

MAIN SWITCH [GRID]

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GRID PROTECTION DEVICE AC Output

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BATTERY

OVER CURRENT PROTECTION

INVERTER / CHARGER

AC Input

UPS ISOLATION SWITCH

NOTE: These items may be integrated into one device

OPTIONAL DC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 3

OVER CURRENT PROTECTION & ISOLATION

Figure 15 - UPS (ESS), WITH RENEWABLE - LAYOUT EXAMPLE

NOTE 3: DC DIRECT BATTERY CHARGING from OPTIONAL RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER and battery types.

LOADS (not backed up by UPS) OPTIONAL UNCONTROLLED AC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO)

[UPS INVERTER]

NOTE 1: The OPTIONAL DC DIRECT CONNECTED RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER.

(GRID)

INPUT

METER (kWh)

NORMAL SUPPLY SWITCHBOARD

UPS (ESS) LAYOUT EXAMPLE (with OPTIONAL RENEWABLE GENERATION)

OPTIONAL DC RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 2

MAIN SWITCH [UPS INVERTER SUPPLY]

OPTIONAL AC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 1

LOADS (backed up

by UPS)

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NOTE 2: The OPTIONAL DC DIRECT CONNECTED RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER.

M

UPS LOADS

METER (kWh)

UPS SWITCHBOARD

M

MAIN SWITCH [GRID]

METER (kWh)

M

ESS LOADS

OPTIONAL UNCONTROLLED AC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO)

LOADS (not backed up by UPS)

MAIN SWITCH [ESS INVERTER SUPPLY]

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Figure 16 - ESS T CONFIGURATION - LAYOUT EXAMPLE

METER ISOLATOR

METER (kWh)

NORMAL SUPPLY SWITCHBOARD

BATTERY

OVER CURRENT PROTECTION

INVERTER / CHARGER

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OPTIONAL DC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 2

OVER CURRENT PROTECTION & ISOLATION

GRID PROTECTION DEVICE

NOTE: These items may be integrated into one device

(with OPTIONAL RENEWABLE GENERATION)

ESS T CONFIGURATION LAYOUT EXAMPLE

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NOTE 2: DC DIRECT BATTERY CHARGING from OPTIONAL RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER and battery types.

NOTE 1: The OPTIONAL DC DIRECT CONNECTED RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER.

OPTIONAL DC RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 1

The ESS system provides support for the load, if the mains fail the ESS shuts down. ESS systems support a bi-directional energy flow, source / load to battery and battery to source / load. Optional renewable generation may be added dependant on manufactures equipment and customer requirements.

4.2 ESS T Configuration

M

MAIN SWITCH [GRID]

LOADS (not backed up by UPS) OPTIONAL UNCONTROLLED AC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO)

MAIN SWITCH [INVERTER SUPPLY]

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Figure 17 - ESS DC TO DC - LAYOUT EXAMPLE

(GRID)

INPUT

METER ISOLATOR

METER (kWh)

NORMAL SUPPLY SWITCHBOARD

The following diagram is a DC to DC ESS system.

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INVERTER

BATTERY

OVER CURRENT PROTECTION

ESS DC to DC Converter / Charger

OVER CURRENT PROTECTION & ISOLATION

(with RENEWABLE GENERATION)

OVER CURRENT PROTECTION & ISOLATION

ESS DC to DC – LAYOUT EXAMPLE

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DC RENEWABLE GENERATION (PV, WIND, HYDRO)

METER ISOLATOR

M

MAIN SWITCH [GRID]

LOADS (not backed up by UPS) OPTIONAL UNCONTROLLED AC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO)

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Figure 18 - CRITICAL LOADS - LAYOUT EXAMPLE

NOTE 3: DC DIRECT BATTERY CHARGING from OPTIONAL RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER and battery types.

NOTE 2: The OPTIONAL DC DIRECT CONNECTED RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER.

NOTE 1: The OPTIONAL AC COUPLED RENEWABLE GENERATION output will be controlled by the ESS to match the load and battery charging requirements.

(GRID)

INPUT

METER (kWh)

MAIN SWITCH [ESS INVERTER SUPPLY]

NORMAL SUPPLY SWITCHBOARD

OPTIONAL DC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 3

OVER CURRENT PROTECTION & ISOLATION

UPS ISOLATION SWITCH

BATTERY

OVER CURRENT PROTECTION

INVERTER / CHARGER

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GRID PROTECTION DEVICE

NOTE: These items may be integrated into one device

(with OPTIONAL RENEWABLE GENERATION)

ESS CRITICAL LOADS – LAYOUT EXAMPLE

M

ESS LOADS

METER (kWh)

OPTIONAL DC RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 2

OPTIONAL AC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 1

LOADS (backed up

by UPS)

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MAIN SWITCH [UPS INVERTER SUPPLY]

UPS SWITCHBOARD

The ESS system has critical loads connected, and if the mains fails then the load/s are supported by the ESS system until the grid returns or alternate generation is operational. ESS systems in this configuration support a bi-directional energy flow, source to load, source to battery, battery to load, battery to source and load to source. Export limiting including (ZERO EXPORT) may be required by some network operators to allow approval for the ESS system.

4.3 ESS Critical Loads

M

NOTE 4

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Figure - ESS OFF-GRID - LAYOUT EXAMPLE

OPTIONAL DC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 3

OVER CURRENT PROTECTION & ISOLATION

SOURCE PROTECTION DEVICE

BATTERY

ESS

M TOTAL LOADS

METER (kWh)

UPS SWITCHBOARD MAIN SWITCH [UPS INVERTER SUPPLY]

NOTE 3: DC DIRECT BATTERY CHARGING from OPTIONAL RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER and battery types.

NOTE 2: The OPTIONAL DC DIRECT CONNECTED RENEWABLE GENERATION may only be available on certain brands / models of ESS INVERTER.

NOTE 1: The OPTIONAL AC COUPLED RENEWABLE GENERATION output will be controlled by the ESS to match the load and battery charging requirements.

OPTIONAL DC RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 2

OPTIONAL AC COUPLED RENEWABLE GENERATION (PV, WIND, HYDRO) NOTE 1

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OVER CURRENT PROTECTION

INVERTER / CHARGER

UPS ISOLATION SWITCH

OFF

SUPPLY CHANGE OVER SWITCH GEN

NOTE: These items may be integrated into one device

OVER CURRENT PROTECTION & ISOLATION

BACKUP GENERATOR CONTROL

OVER CURRENT METER PROTECTION & (kWh) ISOLATION (GEN)

NOTE 4: The SOURCE protection device performs the same function as the GRID Protection Device and prevents export of energy to the SOURCE, only required when the SOURCE can’t accept reverse energy.

BACKUP GENERATION

OFF-GRID SWITCHBOARD

(with OPTIONAL RENEWABLE GENERATION)

ESS OFF-GRID – LAYOUT EXAMPLE

Copyright 2016

LOADS

The ESS system does not have a grid connection. Thus all the energy for the system will be supplied from renewable and optional alternative generation. Recommendations for system design and installation are outlined in AS4509. An example system layout is provided in the following diagram.

4.4 ESS Off Grid (Stand Alone Power System)

5 Selection of Battery Technology 5.1 General The ESS battery technology should be chosen to suit the application. Energy usage patterns, charge/discharge rates, and environmental characteristic are factors that need to be considered.

ESS system safety shall be considered paramount in all phases of the system life cycle.

The Safety Data Sheet (SDS) can provide valuable information with regards to the ESS potential hazards. v

Safety Data Sheet (SDS) 5.2 Safety Data Sheet (SDS) The SDS shall be prepared in accordance with Safe Work Australia's "Code of Practice for Preparation of Safety Data Sheet for Hazardous Chemicals".

The duty of manufacture and importer of a hazardous chemical / material.

NOTES: Refer to Safe Work Australia's web site for more details, http://www.safeworkaustralia.gov.au/sites/swa/about/publications/pages/safety-datasheets-hazardous-chemicals-cop

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5.2.1 SDS - Key Information Areas The SDS is used to provide information on hazards that may be a result of battery failure or normal operation. The key areas are detailed in Table 1.

Table 1 - SDS KEY INFORMATION AREAS

SDS Section Section 1 - Identification: Product identifier and chemical identity Section 2 – Hazard(s) identification

Section 3 - Composition and information on ingredients

Section 4 - First-aid measures Section 5 - Fire-fighting measures

Section 6 - Accidental Release Measures

Section 14 - Transport Information

Key Information Contact information for the importer / manufacture of battery technology Important information required for handling, transport and maintenance activities, this information would be an input to the Safe Method Work Statement The composition of the battery and in particular the electrolyte, the information from this is also critical as an input to assist with determining the battery category Required information to provide first aid in the event of an incident The fire fighting measures provide information to the hazards created by the ESS during a fire. As fire is not part of normal operation of the ESS, this information is critical as an input to assist with determining the battery category.

The accidental release measures provide information on the appropriate ways to respond to the release of chemicals, in the form of spills, leaks or other accidental release. This is so that the adverse effects on people, property and the environment at or near the incident can be prevented or minimised.

This section provides basic classification information for the transportation or shipment of a hazardous chemical by road, rail, sea or air as required by relevant transport legislation.

UN Number, Proper shipping name or Technical Name and Transport Hazard class

In addition to the key areas, the SDS also contains valuable information required during the ESS life cycle. As such the other sections of the SDS are required and are no less important than sections detailed in Table 1.

The UN number is used in conjunction with HB 76, Dangerous Goods - Initial Emergency Response Guide, by fire fighters to expedite emergency response in the event of an accident involving dangerous goods.

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6 Hazards associated with batteries The main types of hazards associated with battery systems are: • Electric shock hazard • Stored energy hazard • Chemical hazard • Flammable emission hazard • Thermal runaway • Transportation • Kinetic energy hazard • Manual Handling Some hazards associated with batteries are not well documented or generally understood, the next revision of this guide will expand on the hazards mentioned above along with detail information in the following areas; • Electric Shock - new requirements detailed IEC 62109 Standard • DC Arc Flash - no details or standards currently cover this area • Toxic atmosphere - no detail on which chemistries may product this hazard under what conditions • Thermal runaway - Chemistry dependant, some are highly unstable, greater detail required to understand the conditions that affect each chemistry • Transportation - transportation of dangerous goods is not well understood in the energy storage industry.

7 Battery Classification The safety classification of batteries can be determined by the information obtained from key areas of the batteries SDS, in addition to results from battery / ESS system testing.

The battery should be classified as belonging to at least one category, depending on the type of battery, internal chemistry and possible failure modes, multiple categories may be applicable depend on failure modes. Battery categories are — • • • • • • •

Category 1 - Un-defined Category 2 - Explosive Atmospheres Category 3 - High Temperature (Thermal runaway) Category 4 - Toxic Atmospheres Category 5 – Hazardous Spills Category 6 – Corrosive Category 7 – Inert

As such, a battery technology may under normal operation be classed as Category 7, but under fault conditions be classed as Category 2. Thus the enclosure shall be compliant to the requirements of Category 2 and Category 7.

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Enslosure Requirements Flow Chart Overall Enclosure Requirements (Category / Categories)

Category 1 (Un-Defined)

Category 2

Category 3

Category 4

Category 5

(Explosive Atmospheres)

(High Temperature)

(Toxic Atmospheres)

(Hazardous Spills)

Category 6

Category 7

(Corrosive)

(Inert)

Figure 19 - ENCLOSURE REQUIREMENTS FLOW CHART

The requirements for each category flow up to the overall enclosure requirements.

7.1 Category 1 - Un-defined This category is used if insufficient information is provided in the SDS and battery performance testing, it is the catch all category, and enclosure capable of this type of battery shall be compliant to categories 2, 3, 4, 5, 6 and 7.

7.2 Category 2 - Explosive Atmospheres A category 2 battery will produce an explosive atmosphere during normal operation or under fault conditions.

7.3 Category 3 - High Temperature A category 3 battery will either operate at high temperatures or under fault conditions burn at very high temperatures. These types of batteries may also include chemistry that required specialised fire fighting equipment or materials to extinguish.

7.4 Category 4 - Toxic Atmospheres A category 4 battery will emit toxic fumes that would create a toxic atmosphere that is either fatal or causes long term medical condition even in very low consternations.

7.5 Category 5 - Hazardous Spills A category 5 battery will produce a hazardous spill if the battery electrolyte were to leak or be spilt. Toxic fumes or other issues may arise from the toxic spill that could cause long term health affects or be fatal. In general, the electrolyte will remain as a liquid and not vaporise completely upon leaking from the battery.

7.6 Category 6 - Corrosive A category 6 battery will produce a corrosive atmosphere if the electrolyte were to be leak or be spilt. Toxic fumes or other issues may arise from the corrosive atmosphere that could affect the battery storage enclosure or cause long term health effects or be fatal.

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7.7 Category 7 - Inert A category 7 battery system will not produce explosive atmosphere, emit toxic fumes, be subject to thermal runaway, produce toxic atmospheres, and produce hazardous spills or corrosive atmosphere. As such the battery still stores energy. There are other potential hazards that still require this category of battery to be protected.

8 Battery Accommodation Batteries should be protected by means of a suitable enclosure. This may take the form of a box, a room or a combination. It should be clean, dry, adequately ventilated, cooled, and provide and maintain protection against detrimental environmental conditions.

The enclosure may be supplied by the battery manufacture as part of the overall ESS or be an additional component The following should be considered to determine the enclosure for the battery system; • Cooling requirements - to maintain temperature within manufactures specifications • Ventilation requirements - to maintain safety under normal operation and fault conditions • Vermin - protection from.

• Maintenance requirements Some aspects associated with batteries are not well documented or generally understood with regards to the requirements for different chemistry, especially some of the more recent battery chemistries. The next revision of this guide will expand on the points mentioned above along with detail information in the following areas;; • Ventilation - how should the enclosure be ventilate, where should the exhaust gas go • Ventilation - of potentially toxic atmosphere for domestic installations • Cooling Requirements - how will the enclosure or ESS system maintain the battery within a safe operation range in Australia's very hot climate.

• Fire Protection - does an enclosure need a particular Fire Rating Level (FRL), what conditions determine when an FRL is required.

• Vermin - what level of vermin protection is required, with system having BMS that maintain the system operation inside safe limits, do you need to prevent vermin from affecting the operation of the BMS and possible catastrophic failure of the ESS.

9 Battery Enclosure Requirements The battery enclosure shall provide suitable protection from the battery technology for the worst case, either during normal operation, during maintenance and under fault conditions. The battery enclosure may be provided by the battery manufacture or as an additional component.

The battery enclosure is effectively the last line of defence, and provides the customer (user) and maintainer the PE (Protective Equipment) to remove the hazard. The Karlsruhe Institute of Technology (KIT), recommend for Li-Ion battery system be housed in a suitable enclosure.

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The specific requirements for each enclosure categories are not well documented for many of the newer chemistries. The next revision of this guide will provide detailed information in the following areas; • FRL requirements • High temperature - requirements for time, thermal protection, what temperature • Toxic Atmospheres - levels of toxic atmosphere, controls to prevent the enclosure being opened if a toxic atmosphere exists, alarms, ventilation.

• Hazardous spill - how long is the spill need to be contained, are in built spill kits / controls required.

9.1 Enclosure Categories In general, a battery may be classified in one or more categories depending on the mode of operation (normal / fault condition). The enclosure for that battery may need to comply with the requirements of more than one category.

9.1.1 Category 1 - Un-defined The Battery Enclosure shall be designed to accommodate batteries of category 1 type.

9.1.2 Category 2 - Explosive Atmospheres The Battery Enclosure shall be designed to accommodate batteries of category 2 type.

9.1.3 Category 3 - High Temperature The Battery Enclosure shall be designed to accommodate batteries of category 3 type.

9.1.4 Category 4 - Toxic Atmospheres The Battery Enclosure shall be designed to accommodate batteries of category 4 type.

9.1.5 Category 5 - Hazardous Spills The Battery Enclosure shall be designed to accommodate batteries of category 5 type.

9.1.6 Category 6 - Corrosive The Battery Enclosure shall be designed to accommodate batteries of category 6 type.

9.1.7 Category 7 - Inert The Battery Enclosure shall be designed to accommodate batteries of category 7 type.

9.2 Enclosure - Egress and Access The Battery Enclosure shall have access to the batteries with sufficient space for safe installation, testing and maintenance. Suggest at least 900mm for batteries up to 150kg in weight, and 1200mm of space for battery cells / mono-blocks that weigh more than 150kg.

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10 Battery Room Requirements The Battery Room requirements are similar to the requirements of a battery enclosure, however as the battery room can be walked into, and then additional requirements may need to apply for some categories.

The specific requirements for battery rooms are not well documented for many of the newer chemistries. The next revision of this guide will provide detailed information in the following areas; • Toxic atmosphere - detection systems, which chemistries need this, and what levels are safe.

• Toxic / corrosive spill - requirements and other systems that need to be in place to mitigate disaster.

• High temperature batteries / faults - do rooms require fire suppression systems, and which type are suited to which chemistry • Egress and Access - what requirements around larger batteries, some weights are up around 300kg per cell • Remote shutdown • Remote monitoring - of system health and safety

11 Installation The current National Construction Code (NCC) divides buildings into classes. Class 1 & 10 are domestic dwellings where as class 2 through 9 are non-domestic dwellings.

The NCC provides guidance for class 2 through 9 however does not cover class 1 & 10 in detail.

The Australian Standard AS4086, AS3011 and AS4509 cover installation of battery systems. The standards are written around Lead Acid technology and don't account for the new chemistries and grid hybrid systems.

The metrology detailed in the current standards can be applied, a chemistry non specific standard is required to cover a broad range of possibilities.

The specific requirements for installation are not well documented for many of the newer chemistries. The next revision of this guide will provide detailed information in the following areas; • Detailed requirements - domestic ESS installation locations, permissible locations • Physical requirements - (size, weight), minimum area, access • Battery technology - additional requirements based on chemistry • Ventilation requirements - how venting is to be achieved, where is it permissible and not permissible • Environmental considerations, e.g. temperature, exposure to direct sunlight, weather, etc.

• Intended use of the location • Access for emergency services • Remote shutdown capability - when is it required • Access control • Cabling - methods of protection, sizing • Electrical - installation, switchboards, control systems, layouts • Network - information required by network operators

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12 Labelling All electrical equipment shall be marked (labelled) according to the requirements for marking to local standards and regulations when applicable.

The labelling for battery storage system is more extensive than a standard grid connected solar system. Also additional labels will be require for ESS system that are not currently covered by AS4777, AS5033 or AS4509. As such this section will provide guidance on how the ESS system should be labelled.

The specific requirements for additional battery signage are not well documented for many of the newer chemistries. The next revision of this guide will provide detailed information in the following areas; • Warning sign Battery - for use by emergency services • Labelling of switchboards - greater details and information on how UPS, Normal Supply and Off-Grid switchboards should be labelled.

• Labelling requirements - chemistry specific, what information needs to be provided • Spark & Arc Flash Hazards - what signs and information is required.

• Battery Rooms - requirements for additional information • Installer Guides - Quick Reference for labelling.

• Label Quality - requirements on how long a label should last, UV, fire, heat

12.1 FIRE EMERGENCY SERVICES INFORMATION The introduction of different battery chemistries presents a significant risk to emergency service personal. As chemistry specific response methods are required.

The Australian Standard HB76 Dangerous Goods - Initial Emergency Response Guide details how the emergency service should respond.

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12.1.1

Warning sign Battery

In addition to other signs specified by Australian Standards, a sign with a rectangular green reflector at least 150 mm (wide) and 100 mm (high) shall state the following inside the battery picture: BATTERY CHEMISTRY (Predominate) UN No: (UN number associated with predominate battery chemistry) NOTE: The chemistry and UN No shall also be engraved / stamped into the steel sign.

The sign shall be placed on or immediately adjacent to the meter box and main switchboard, so as to be readily visible to approaching emergency workers.

BATTERY CHEMISTRY UN No: CHEM:

UN:

Figure 20 - BATTERY SIGN

12.1.2

ESS Sign Overview - Example

The labelling of ESS system is complex and requires many different signs that are dependant on chemistry of the batteries and the configuration of the system.

The following diagram provides an example for label requirements.

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Figure 21 - ESS SIGNAGE OVERVIEW

13

Documentation

The documentation require for the ESS life cycle is defined by the following areas; • Manufactures Documentation - Installation Manual, product specifications, data sheets, certificates of compliance, warranty statements • Information relating to operation - information derived from manufactures manual and site specific information • Information relating to maintenance - information derived from manufactures manual and site specific information • Network Operator - minimum information required by network operator • HAZCHEM Register - register of all ESS systems for use by emergency services Additional information is required in the following areas; Manufactures Documentation - only maintained for manufacturing life of product, not the service life of product Installation Manual - minimum required information to complete installation safely User manual - minimum required information to be included Maintenance - minimum required information to be included Stewardship - information relating to recycling and disposal of ESS

14 Commissioning The process for commissioning of the ESS system is dependant on ESS equipment and configuration.

Australian Standards detail mainly lead acid based commissioning. Manufactures documentation details chemistry specific.

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Additional detail covering the following areas will be provided in the next revision of this guide; • Check List - covering chemistry non-specific checks • Check List - covering chemistry specific checks, this may include brand specific checks • Audits - what level of auditing is required to ensure compliance and safety.

15

Maintenance

The frequency of maintenance to be carried out on an ESS system is dependant of the type of technology, manufactures recommendations, customer site, network operator requirements and customer requirements.

The current Australian Standards provide some guidance on the frequency of maintenance. Different network operators require different frequency of maintenance.

Additional detail covering the following areas will be provided in the next revision of this guide; • General Maintenance Requirements - non chemistry specific and chemistry specific • Electrical equipment - manufactures, network operators and site specific requirements for particular types of ESS equipment.

• User Accessible Areas - maintenance is suitable for user, access & egress for user, requirements for hazard mitigation during user maintenance • Maintainer Accessible Areas - access & egress for maintainer, requirements for hazard mitigation during maintainer maintenance activities, WHS requirements • Training and accreditation for maintainer - manufacture specific and national accreditation

16

Stewardship

At a point in time after the ESS system has been commissioned, the ESS system will reach the end of it's life. As a number of new chemistries currently don't have common recycling process in place it is difficult for the consumer to ensure the equipment is recycled correctly.

Without a pre-defined process in place, hazardous materials may end up in land fill creating environmental issues.

Product stewardship is critical to the ESS system life cycle, and planning for the disposal should be undertaken at the installation stage.

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Additional information is required in the following areas; • Chemistry specific stewardship guidelines • Lists of recycling centre/s - that will accept the various chemistry • Manufacture based recycling - fall back plan if manufacture / importer no longer exists • Education and Training - training of existing recycling centres to understand the various chemistries / equipment that may be presented to them and the associated hazards

17

Australian Standards

The current Australian Standards don't cover many critical areas creating potential safety hazards for ESS installers, ESS owners / operators and the general public.

The number of ESS systems are steadily increasing, the quality and safety of these systems ranges from barely adequate to systems that employ multiple levels of redundant safety systems.

As a matter of urgency, a new Australian Standard is required to ensure that the barely adequate ESS systems are moved into an adequate safety zone. A non chemistry specific standard is required to address the impending safety issues associated with the increasing number of ESS systems being installed.

The research conducted by CSIRO, KIT and DNVGL along with many other organisations indicates unless a new standard is developed and released soon the potential for damage to property and life will be much greater than the issues associated with installation of insulation in Australian houses.

URGENT ACTION is required in the following areas; • Development of ESS Best Practice Guide - interim standard for ESS sales, design and installation • Development of ESS Australian Standards AS5139.1 - Sales, Design & Installation • Development of ESS Battery Safety Testing - AS5139.2 - Chemistry specific safety tests for batteries, BMS, ESS systems • Approved products list - whitelist of products approved for use in Australia and network operator areas

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The Australian Battery Guide by

Copyright 2016