Battery energy storage systems (BESS)

The first step is to identify the hazards. They can result from the actions of people working with the battery system or the battery system itself, including its installation and location.

Ask yourself:

• Has the right battery technology been chosen for the application?
• Is it installed according to the manufacturer’s instructions, industry standards and guidelines, and building codes?
• Could the system overheat or over-charge?
• How would an accidental chemical spill be managed and contained?
• Are workers trained to safely handle, use and maintain the battery system?

Talk to your workers and ask:

• Are you aware of any potential hazards?
• How can we improve our safety and our processes?
• Do you know how to report a hazard?

Regularly review your own records, and consider:

• What do your workers’ compensation claims, recorded incidents, sick leave and worker complaints tell you about past incidents and hazards?
• What can you do to prevent the same things happening again?

Identifying hazards should be an ongoing activity and something organised at least once a year, or whenever there is a change in equipment, facilities or work practices.

Next, assess the level of risk posed by each hazard. The risk level is determined by:

• how serious the potential harm is
• how likely it is to happen.

You can use this risk assessment template (DOCX, 0.02 MB) to guide you and record your assessments.

The law requires you to eliminate the risks if practical, or to minimise them as much as possible.

You must work through the hierarchy of controls to choose the control that most effectively eliminates or minimises the risks. This may involve a single control measure or combination of two or more different controls.

Find the hierarchy of controls in How to manage work health and safety risks code of practice 2021 (PDF, 0.65 MB) or use the Electrical safety code of practice 2021 - Managing electrical risks in the workplace.

Additional ways to control the risks associated with battery energy storage systems are as follows.

A. Choose the right battery technology for the application

A range of battery technologies are available in Australia, including:

• lead-acid (advanced, flooded-cell and sealed)
• lithium (ion and polymer)
• nickel-based (metal hydrides and cadmium)
• flow (zinc bromine and vanadium redox)
• hybrid ion.

Different battery technologies and chemistries have different performance capabilities, and different requirements for installation, operation and maintenance. Choose a battery technology that suits the application and know how to safely handle (including transporting), install and operate the system.

B. Design the battery system to suit the application

Required energy storage capacity, budget, battery technology, type and intended lifespan will all influence the design of the battery energy storage system, as will applicable standards, industry guidelines for best practice, and the manufacturer’s recommendations.

You should also think about:

• the physical size required for the installation
• necessary building modifications, which may need local council approval
• the type of electrical switching and protection devices, cable sizes, inverter size and the overall reliability and compatibility of the various electrical components in the system
• compatibility with an existing solar PV system or local electricity grid
• whether the system will export electricity to the local grid to maximise tariff returns
• a suitable emergency plan that the customer can manage.

Source components that are suited to Australia’s climate and only buy from businesses that have product expertise, aftersales service, warranty, replacement components and ready access to spare parts.

C. Find the right location for the installation

A battery energy storage system is a fixed installation, so it’s important to assess the risks of the technology being used in that location.

This includes complying with any requirements specific to the choice of location according to:

• AS/NZS 3000 (the wiring rules)
• AS/NZS5139 Electrical installations – Safety of battery systems for use with conversion equipment
• supplier (the manufacturer/importer) instructions.

It’s also important to consider:

• any building codes that apply to batteries (national and local) and changes to floor loadings
• whether the location complies with the manufacturer's recommendations to protect the system from weather and extreme heat, light and temperature, which may reduce performance or the lifespan of the system
• how any electrolyte spills will be captured to avoid exposure to hazardous chemicals and damage to equipment or the environment
• using the correct fire-rated walls to avoid the spread of fire, should it occur
• allowing suitable access to the area during installation and maintenance work
• ways to achieve adequate ventilation
• protecting it from being hit by vehicles or other objects in the yard.

All locations and installations should restrict access by untrained people, children, pets or vermin.

D. Safely install the battery system

Ensure safe work practices are followed, and compliance with the manufacturer’s guidelines and instructions, legislation, the wiring rules and other relevant standards are achieved during installation.

You should also:

• insulate live parts to prevent electric shock, including battery terminals and other electrical connections
• know how to test, commission or de-commission the system, as required
• ensure there is sufficient clearance between items to prevent overheating
• ensure shutdown switches are easily accessible
• place signage and warnings to clearly identify equipment and shut-down procedures and the battery chemical being used (so it can be identified by emergency workers)
• be aware of the hazardous chemicals in batteries and taking precautions, including having the appropriate safety data sheets nearby.

E. Correctly test and commission the system and explain the maintenance requirements

Test and commission the system according to the manufacturer’s instructions and relevant standards.

Explain the maintenance requirements to the system’s owner, to maximise its life and performance. They will need to:

• know how to safely operate, maintain and shutdown the system in an emergency
• understand various safety warnings and lights, specific to the system
• know which safety data sheets are required and where they should be located
• know where to locate the serial number to help traceability should a recall occur
• know what maintenance is required, when it should be scheduled, and who should do it
• visit the Electrical Safety Queensland website for more information on BESS.

F. For lithium-based battery storage equipment, also follow the best practice guide

Use the Best Practice Guide: Battery Storage Equipment – Electrical Safety Requirements for minimum levels of electrical safety for lithium-based battery storage equipment. Products covered in this guide include battery storage equipment with a rated capacity of equal to or greater than 1kWh and up to and including 200kWh of energy storage capacity when measured at 0.1C.

The guide includes suggested safety requirements for:

• battery modules (BM) – one or more cells linked together for use in other equipment
• pre-assembled battery systems (BS) – a complete package for connection to a DC bus or DC input of power conversion equipment (PCE)
• pre-assembled integrated battery energy storage systems (BESS) – a complete package that has AC output for connection to the electrical installation.

The guide includes details of what should be supplied with the equipment, including:

• declaration of compliance or certification
• technical datasheets and safety data sheets
• installation, operating and maintenance instructions.

The guide does not cover electrical installation requirements for batteries. Installation of battery storage equipment referred to in the guide should still follow appropriate safety standards. Installation safety practices should include undertaking a suitable risk assessment and adherence to the manufacturer's instructions, industry accepted guides, AS/NZS 3000 (the wiring rules) and AS/NZS5139 Electrical installations – Safety of battery systems for use with conversion equipment.

You should regularly review your control measures. Don’t wait for something to go wrong. If necessary, change or adjust your approach. The aim is to maintain a work environment that is without risks to health and safety.

Work health and safety laws require you to review controls:

• when you become aware a control measure is not working effectively
• before a change that might introduce a new risk
• when you find a new hazard or risk
• after a near-miss
• when your workers tell you that a review is needed
• after a health and safety representative requests a review.