Requirements for Energy storage systems (ESS) 2014-10-14 Ralf Martin Müller
1 TÜV Rheinland 2 Risks, Hazards 3 ESS Application and Conditions of Operation 4 Standardisation - Focus on Safety und Quality 5 Testing Batteries and Inverters
TÜV Rheinland History. Milestones. 1872 Founded to ensure the safety of manufacturing plants 1900 First Vehicle Inspection 1960 First Product Certification 1970 First Foreign Subsidiary 1997 Merger with TÜV Berlin-Brandenburg 2005 Integration of LGA! Our goal is to be the world s best independent provider of technical services for testing, inspection, certification, consultation and training. TÜV Rheinland LGA Products GmbH 46 16.10.2014
At Home on All Continents. Figures 2013 Sales in Mio. 1,600 - abroad in % 48,4 EBIT in % 7,3 Employees 18,000 - abroad in % 59 Locations: more than 500 in 66 countries TÜV Rheinland LGA Products GmbH 47 16.10.2014
1 TÜV Rheinland 2 Risks, Hazards 3 Battery - Application and Conditions of Operation 4 Standardisation - Focus on Safety und Quality 5 Testing Batteries and Inverters
Batteries - Causes for risks and hazards Cause Defect in manufacturing & manufacturing problems Discontinuous cooling Effect Intern short circuit, overheating damage Overheating damage Faulty charging device Overcharging heating damage Incorrect use or accident Short circuited cells or poles overheating damage...... 50
Example: Risk potentials with Lithium-Ion Storage systems Typical characteristics Electrical voltage Electrical current Material durability with inflammation range Energy density of Li-Ion vs Fuel But Li-Batteries 2 800 V 1...2000 A combustive (electrolyte) 20 200 C 150 1.500 Wh/kg 12.800 Wh/kg (Bild: dpa) Energy density (Lithium): Ethermal > 10x Electric and therefore an exothermic risk potential comparable to fuel! 51
1 TÜV Rheinland 2 Risks, Hazards, 3 Battery - Application and Conditions of Operation 4 Standardisation - Focus on Safety und Quality 5 Testing Batteries and Inverters
Current field of application and demand of qualification 30TWh = 4,8% of power generation in Germany out of 1,4 Mio. plants on sunny days 35% covering through PV and up to 10% through wind Demand for secure and reliable storage solutions 53,4 TWh = 8,5% of power generation in Germany with 23.000 plants 53
Fixed batteries and industrial operation conditions Fixed industrial applications: - Use under standard-industrial environment - EMC, dust, heat/fire, humidity, etc. - Use under offshore environment - additional saline atmosphere and high solar irradiation -Use under agricultural conditions additional nitrogenous, ammonium atmosphere and solar irradiation - Use under geologic/geographical conditions Commotion, earthquake 54
Residential batteries in private sector Fixed applications in privat sector/home area - Incorrect use short circuit - safety against overloading - EMC Influences inverter, ITC EMC - Design - Fire in area of heating system robustness - Water/flooding in cellar and deep level as well as dust and humidity IP degree of protection claims standardised requirements and tests 55
1 TÜV Rheinland 2 Risks, Hazards 3 Battery - Application and Conditions of Operation 4 Standardisation - Focus on Safety und Quality 5 Testing Batteries and Inverters
Standardisation for Safety & Quality * Further organisations like BSI, SAE, ANSI, BATSO 57
Standardisation for Safety & Transport UN 38.3 Requirements and tests for transportation of lithium-batteries 38.3.4.1 Test T.1: Altitude simulation 38.3.4.2 Test T.2: Thermal Test 38.3.4.3 Test T.3: Oscillation 38.3.4.4 Test T.4: mech. Stroke 38.3.4.5 Test T.5: External Short circuit 38.3.4.6 Test T.6: Crash (cell) / Crush (pack) 38.3.4.7 Test T.7: Overcharge (pack) 38.3.4.8 Test T.8: Enforced Discharging (cell) 58
Current status of standardisation Fixed energy storage systems and safety issues IEC and DKE AK 371-05 develop /discuss currently: - The IEC 62619 (Li-Ion storage systems for industrial applications) - The 21A/520/NP:2013-04 (VDE AR 2510-50) The Technical Commitee of BATSO developed the standard BATSO 02 with following content respectively structure of requirements: 1. Fixed energy storage systems in residential buildings; Flooding, earthquake, fire, misuse, dust and climate 2. Fixed energy storage systems in industrial buildings; Flooding, earthquake, fire and dust 3. Fixed energy storage systems placed outside (outdoor installation); Flooding, earthquake, dust and water, solar irradiation, temperature and humidity 4. Fixed energy storage systems for offshore-applications (together with outdoor installation"); Flooding (increased demands), solar irradiance, durability against saltmist 60
Current status of standardisation Catalogue of safety objectives for residential Lithium-Ions storage systems The Catalogue has been developed with cooperation of the following institutions (Stakeholder): - Bundesverband Batteriespeicher (BVES), - Bundesverband Solarwirtschaft (BSW-Solar), - Zentralverband Elektrotechnik- und Elektronikindustrie e.v. (ZVEI), - Deutsche Gesellschaft für Sonnenenergie (DGS) - StoRegio e.v. - TÜV Rheinland, - Verband der Elektrotechnik (VDE), - CETECOM - Karlsruher Institut für Technologie (KIT). 61
Current status of standardisation Catalogue of safety objectives for residential Lithium-Ions storage systems The catalogue defines safety objectives for battery storage systems with and without inverter. These safety objectives refer to rechargeable Lithium-Ion-cells (secondary- Lithium-Ion-cells) for fixed residential storage systems : e.g.:applications combined with Photovoltaic systems The catalogue implements current and upcoming standards and provides an overview for necessary investigations to guarantee a safe system. TÜV Rheinland investigates and certifies lithium-ion battery-systems for residential applications in terms of safety, performance and lifetime; Based on BATSO 02:2013, TÜV Rheinland 2PFG safety and qualitystandards. 62
1 TÜV Rheinland 2 Risks, Hazards 3 Battery - Application and Conditions of Operation 4 Standardisation - Focus on Safety und Quality 5 Testing of Batteries and Inverters
Battery testing residential application BATSO 02:2013 Fire The battery should be able to resist an external fire at least 30 min. The test is defined in DIN EN 13501. Water/Flooding The battery system should be able to resist immersing under a 30 cm head of water. That can be enabled with the enclosure or an appropriate mounting spot. For floor installation, tests are defined in EN 40050-9, IPX8. (in 50cm depth of water for 90 minutes) 64
Battery testing residential application Dust The enclosure of the storage system should provide IP5X degree of protection (EN 60529). Misuse The enclosure of the storage system should be furnished with screws (or different closure technology) to assure, that opening is only possible with special tools. In addition an IP4X degree of protection (EN 60529) must be obtained. [source: SMA] 65
Battery testing mechanical requirements Test Item Examples Requirement Examples Vibration IEC 62660-2 21/709/CDV Penetration SAE J 2464 Drop FreedomCAR Immersion UL subject 2580 Roll-over simulation Mechanical Shock VDA UN Model Regulation Crush IEC 62660-2 21/709/CDV 66
Battery testing electrical requirements Test Item Examples Overcharge Requirement Examples FreedomCAR Forced discharge IEC 62660-2 21/709/CDV External short UN Model Regulation Imbalanced charging UL subject 2580 Charger compatibility UL subject 2580 Partial short circuit Impedance R,X,IZI VDA Manufacturer 67
Battery testing electrical requirements Test Item Examples Overcharge Requirement Examples FreedomCAR Forced discharge IEC 62660-2 21/709/CDV External short UN Model Regulation Imbalanced charging UL subject 2580 Charger compatibility UL subject 2580 Partial short circuit Impedance R,X,IZI VDA Manufacturer 68
TÜV Rheinland ESS-Battery testing lab Safety, Power & Life-time investigations Cell testing Manufacturer: FuelCon 4CH 100A / 5V Module testing Starter Batteries Digatron Manufacturer: ESPEC & FuelCon 4CH 800A / 100V 6CH 1200A / 30V 69
Inverter safety and grid conformity Inverter, safety EN 62109-1 - Safety of power converters for applications in photovoltaic systems - Part 1: General requirements EN 62109-2 - Safety of power converters for applications in photovoltaic systems - Part 2: Special requirements for inverters 70
Inverter safety and grid conformity Inverter, Grid conformity VDE-AR N 4105 for UK: G 83/1 or G 59/2 - Generators connected to the low-voltage distribution network - Technical requirements for the connection to and parallel operation with low-voltage distribution networks VDE 0124-100 - Grid integration of generator plants - Low-voltage - Test requirements for generator units to be connected to and operated in parallel with low-voltage distribution networks FNN Note for storage systems 05/2013 - Amendment to VDE AR 4105 (delivery of energy) - Techn. guideline emergency generator (isolated operation) - It is not permitted to take power from the grid and to feed in again. 71
Conformity evaluation for ESS Guidelines & Standards Generally at least: UN T 38.3 EMC Guideline 89/336/EWG BMS (BMU), protection electronics Guideline 2006/66 (introduction in the market, environmental compatibility, recycling) Application-specific guidelines for special environments (medical.or explosion-risky area) Standards Application-specific; Industrial- or residential area IEC 62619, EN 50272-2, IEC 61427-1, EN 50272-2, VDE AR 2510-2-50, VDE 0100/410, Batso 02, EN 61508, EN 62109-1/2 + Grid code requirements 72 VDI Wissensforum - Bonn - Stephan Scheuer
Energy Storage System certification TÜV Rheinland 2PFG residential 2353 storage systems (analog Catalog of safety objectives ) TÜV Rheinland 2PFG 1306 Performance & Lifetime tested Performance Lifetime 73
Conclusion 1. Energy storage systems carry potential risks and hazards, which should be controllable due consideration of technological knowledge and specific application. 2. Applied tests for ESS imply a combination of electrical and mechanical tests in consideration of defined environmental conditions. 3. Standardized tests and certifications in regard to safety and performance establish confidence for the manufacturer when designing products and trust for the enduser. 74
Thank you for your attention! Ralf Martin Müller +49 221 806 3423 mueralf@de.tuv.com 75 16.10.2014 TÜV Rheinland LGA Products GmbH