UL9540 Overview:

Safety for Energy

Storage Systems

Ken Boyce
Principal Engineer Director
Energy & Power Technologies
UL LLC

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Leader in Advanced Battery Safety Science

Research

Design Thought
Advisory Leadership

Battery UL 1973: Stationary Applications

Testing & Standards UL 2580: Electric Vehicles
Certification UL 2271: Light Electric Vehicles
UL 2272: Electrical Systems for Self-
Balancing Scooters
UL 810A: Electrochemical Capacitors
UL 2743: Portable Power Packs
UL 9540: Energy Storage Systems
UL 3100: Distributed Energy
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Battery Science converted to UL 9540

UL originally published UL 9540 in 2014 to address

safety of energy storage systems

The work was based on our extensive safety science

and engineering efforts to effectively mitigate potential
hazards for energy storage systems

The requirements address the inherent design and

performance, as well as the interface of the energy
storage system with the infrastructure

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UL 9540 - Scope

energy storage systems that are

intended to receive electric energy and
then to store the energy in some form
Scope includes: to provide electrical energy to loads or
power conversion equipment when
needed

The systems covered can be:

• Standalone to provide energy for local loads; or
• In parallel with an electric power system, electric utility grid; or
• Able to perform multiple operational modes.
• For use in utility-interactive applications in compliance with
IEEE 1547 and IEEE 1547.1 or
• Other applications intended to provide grid support functionality,
• May include balance of plant and other ancillary equipment of the
system

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UL 9540 Safety Approach

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 UL 9540 Scope
Input Energy Power
Conversion Conditioning
Electrical Power Mechanism Electrical power
System
Signals, Communication Signals, Communication
Energy Output Energy
Ventilation Exhaust, Heat, Other Wastes
Storage Conversion
Fuel
Mechanism Mechanism
Coolant/water, etc.

Input & Output Other Balance Environmental

Interface of Plant Controls
Equipment Equipment Equipment
Equipment

Figure 1 – Block Diagram of Electrical Energy Storage System

Technology Input Energy Conversion Energy Storage Output Energy Conversion

Mechanism Mechanism Mechanism
Electrochemical Charger Battery Converter
Chemical Water Electrolysis H2 Hydrogen Storage Fuel Cell
Generator
Mechanical Air Compressor Flywheel Motor Generator
Thermal Heat Pump Thermal Storage Heat Generator 6
 Potential Hazards Associated with Energy
Storage Systems

Energy Electrical Mechanical Chemical

What are the
potential
hazards
associated
with ESSs? • Fire Toxic or
• Electric • Pressure
• Explosion shock • Noise hazardous
• Burns • Arc Flash • Moving substance
• Electrical exposure/
parts
burns • Sharp concentrations
edges

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Safety Analysis Approach

Energy storage systems shall be

provided with a safety analysis such
as, but not limited to:
• A failure modes and effects analysis (FMEA)
that identifies critical safety components and
circuits of the system shall be provided.
• The analysis shall consider the compatibility
of the parts of the energy storage system
with regard to safety of the overall system.
• Electronics and software controls determined
to be critical for safety
• evaluated for functional safety to an
appropriate safety integrity level (SIL) or
• similar safety classification for the system
as determined by the system safety
analysis
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Safety Analysis Approach

FTA is a top down analysis

FMEA is a bottom up analysis

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Referenced Critical Standards
UL 1973, Batteries for Use in Light Electric Rail (LER) and
Stationary Applications
UL 1741, Inverters, Converters, Controllers and Interconnection
System Equipment for Use With Distributed Energy Resources

ASME B31, Power Piping Codes

ASME B & PV, Boiler and Pressure Vessel Code

ASHRAE 62.1, Ventilation for Acceptable Indoor Air Quality

CSA FC 1, Fuel Cell Technologies – Part 3-100: Stationary Fuel

Cell Power Systems – Safety

IEEE C2, National Electrical Safety Code

NFPA 70, National Electrical Code (NEC)

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Construction Criteria

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Overview of UL 9540 Construction Criteria
Enclosure & Electrical
Insulation Materials -

• Plastic Materials • Openings evaluated per

Enclosure Ratings –
• Comply with either UL IEC 60529 rating
746C or C22.2 No. 0.17 • Minimum rating IP2X
• For enclosures or unless intended for
insulation Restricted Access
• 5VA minimum flame Locations
rating for plastic • Outdoor enclosure ratings
enclosures evaluated
• UV rating for enclosure
if exposed to sunlight
• Metallic Materials
• Resistant to
corrosion

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 Overview of UL 9540 Construction Criteria

• Prevent access by • Worker safety per NFPA 70E

Walk In Enclosures

General Electrical Safety

unauthorized persons or CSA Z462
• Workspace requirements per
• Provide means for NFPA 70 or CEC C22.1 or
egress IEEE C2
• Entrances opened from • Protection against worker
inadvertent contact with
inside without use of a hazardous parts
tool • Lightning and surge protection
• Provided with sufficient • Need to isolate/disconnect
ventilation (ASHRAE equipment
• Determination of Arc Flash
62.1) Hazards through assessment
• Lighting per 70E
• Arc flash incident level
• Restricted approach
boundary
• Arc flash PPE
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 Overview of Construction Requirements

• Connections per NFPA 70 or • Remote controlled

Components

Remote Controls,
Communication
Electrical Connections &

CEC system provided with

• Provision for connection of a
wiring system local disconnect
• Sizing of field wiring • Identification of
connections & field wiring communications
sizes protocols to be used
• Disconnect device
• Protection of internal wiring
• Transformers to be dry type
unless installed outdoors
• Fuses rated for fault current
• Spacings and Insulation levels

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 Overview of Construction Requirements

• A safety analysis of the • Piping

Safety Analysis

Fluid Handling &

Containment
system is to be provided • ASME Codes for Power
• Guidance obtained from
standards such as: Piping, ASME B31 (all
• IEC 60812 applicable parts) or CSA
• IEC 61025 B51, B52, Z662
• MIL-STD-1629A • Pressure Vessels
• Electronics and/or software
• ASME BPVC and CSA
determined critical to be
evaluated for functional safety B51
• Based upon determined SIL
or level
• UL 991/CSA C22.2 No. 0.8
• UL 1998
• UL 60730-1
• IEC 61508

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 Overview of UL 9540 Construction Criteria

• Piping: • Vented • Maintain

Containment of Moving Parts

• Contain
Fluid Equipment

Hazardous Spill Containment

Combustible Concentrations
ASME Codes Batteries or loose or concentra-
for Power other types broken tions at
Piping, of batteries parts - 25% LFL
ASME B31 requiring evaluate under
(all maintenance through maximum
applicable of electrolyte testing operating
parts) or or potential conditions
CSA B51, for spills. • Shutdown
B52, Z662 upon
• Pressure failure of
Vessels: required
ASME BPVC ventilation
and CSA B51 • Maintain
electrical
compart-
ments at
positive
pressure
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 Overview of UL 9540 Construction Criteria
• Conduct a fire risk
Markings
Fire detection & suppression
assessment
• If determined that fire
detection and suppression is
necessary
• Install in accordance with
technology and local
codes where equipment is
to be sited
• If not part of ESS, include
guidance in installation
manual for suitable fire
detection and suppression
system to be in stalled.
• Nameplate markings
• Current, Voltage and Power
(output and input)
• Energy output
• No. of phases and frequency
• Duty cycle (if applicable),
• Ambient temperature range,
• Maximum short circuit current
• Special environmental ratings
• Dimensions and weight
• Grounding symbols where
necessary
• Hazardous voltage and arc fault
warning labels
• Warning to read all safety
instructions and labels
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 Overview of UL 9540 Construction Criteria

• All information

Operating & Maintenance Instructions

• Instructions for • Routine service
necessary for the
General Instructions

Installation Instructions
installation, installation and information
operation and commissions of ESS • Maintenance
maintenance including fuel, electrical instruction for
• In accordance with
and fluid connections, service personnel
the Technical communications, and minor routine
Documentation special environmental instructions for
section, Section 17 considerations, and operators
of the Electrical equipment needed to • Decommissioning
Standard for install the ESS. instructions and
Industrial • Restricted access instructions on
Machinery, NFPA locations information disposal of waste
79 • Eye wash stations if materials
• Warning marking
flow batteries, etc.
information • Installation instructions
• System
per code criteria
Specifications • Special handling
procedures during
installation

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Testing Criteria

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Overview of UL 9540 Tests

EES Electric Mechanical Fluid Environ-

tests containment mental
system tests
tests
tech- tests
nology
tests
• Normal
operations • Over speed • Special
• Dielectric • Faulted • Leakage
• Strength Environment
voltage securement Installations
withstand • Blocked shaft
• Impulse • 5 Maximum
• Equipment Abnormal
grounding Operating
and bonding Speed
• Insulation • Mechanical
resistance Failure
Qualification
(production)
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Summary

UL 9540 was the world’s first safety standard published

to address energy storage systems

It is the national standard for energy storage system

safety in the United States and Canada, and is
influencing designs of products being deployed
around the globe today

Connections with IEC TC120 and others will support

the best use of the UL 9540 effort to address global
safety

21
Thank you
Ngiyabonga
Dankie

Ken Boyce
Kenneth.p.boyce@ul.com

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