GB/T 42314-2023Guide for hazard sources identification of electrochemical energy storage station (English PDF)

Foreword

This document was issued on 17 March 2023 by the State Administration for Market Regulation; Standardization Administration of the PRC and takes effect on 1 October 2023.

It is a GB/T standard: recommended rather than compulsory, but it is the text a Chinese reviewer applies when assessing a submission.

1 Scope

GB/T 42314-2023 covers how the hazards inside an electrochemical energy storage station are found, described and ranked. The overall requirements tie the exercise to the laws, regulations and technical standards in force and to the hazardous and harmful factors actually present on the site, so that the list is station-specific rather than generic. The identification methods clause sets out the techniques the work may use — the safety checklist, preliminary hazard analysis, the operating condition hazard assessment and the analytic hierarchy process — each set out in an informative annex, so that two teams looking at the same station reach comparable findings. The longest clause is the identification content, which works through the hazard sources carried by the equipment and facilities themselves, down to items such as electrical clearance in a hydrogen supply pipeline or a missing confirmation on secondary containment. A final clause turns those findings into hazard levels, which lets an operator separate what needs an engineered control from what can be managed by procedure. A hazard nobody has written down is a hazard nobody has assigned a control to, and a room full of stored electrochemical energy gives little warning before it becomes a fire. Written for the owners, designers and operating staff of energy storage stations and for the assessors who review their safety documentation.

This document specifies the content of hazard sources identification and the requirements for

hazard level classification of electrochemical energy storage stations, and describes the method

of hazard sources identification.

This document is applicable to the hazard sources identification in the operation, overhaul,

maintenance and testing of electrochemical energy storage stations using lithium-ion batteries,

flow batteries, lead-acid (carbon) batteries, sodium-ion batteries and water electrolysis

hydrogen production / fuel cells as the carrier.

2 Normative References

The contents of the following documents constitute indispensable clauses of this document

through the normative references in the text. In terms of references with a specified date, only

versions with a specified date are applicable to this document. In terms of references without a

specified date, the latest version (including all the modifications) is applicable to this document.

GB/T 6441 The Classification for Casualty Accidents of Enterprise Staff and Workers

GB/T 13861 Classification and Code for the Hazardous and Harmful Factors in Process

GB 18218 Identification of Major Hazard Installations for Hazardous Chemicals

DL/T 2528 Basic Terminology of Electrical Energy Storage

3 Terms and Definitions

What is defined in DL/T 2528, and the following terms and definitions are applicable to this

document.

3.1 hazard sources

The sources or conditions that may result in personal injury, property damage or environmental

destruction.

[source: NB/T 10575-2021, 3.1, modified]

3.2 hazard sources identification

Identify the existence of hazard sources and determine hazardous factors and harmful factors

that may cause personal injury, property damage or environmental destruction.

[source: NB/T 10575-2021, 3.2]

3.3 hazardous factors

Factors that can cause casualties to people, relatively large losses to property or sudden

destruction to the environment.

[source: NB/T 10575-2021, 3.3, modified]

3.4 harmful factors

Factors that can affect people’s physical health, cause diseases, or certain losses to property, or

chronic damage to the environment.

[source: NB/T 10575-2021, 3.4, modified]

4 Overall Requirements

4.1 The identification of hazard sources of electrochemical energy storage stations shall be

based on relevant laws, regulations and technical standards, identify various hazardous and

harmful factors existing in the electrochemical energy storage stations, and identify various

hazard sources of the electrochemical energy storage stations.

4.2 The identification of hazard sources of electrochemical energy storage stations shall cover

all equipment, facilities, sites, operation and overhaul operation activities of the electrochemical

energy storage stations.

4.3 The identification of hazard sources of electrochemical energy storage stations shall include

unsafe conditions of equipment and facilities, unsafe behaviors of people, and unsafe factors of

the environment, etc.

4.4 The classification of hazardous and harmful factors of electrochemical energy storage

stations shall be carried out in accordance with the stipulations of GB/T 13861, and the

classification of possible impacts shall be carried out in accordance with the stipulations of

GB/T 6441.

4.5 In accordance with the hazard level, the hazard sources of electrochemical energy storage

stations can be classified into major hazard sources and general hazard sources. Those that may

cause casualties or property losses that reach the stipulations of Regulations on Reporting,

Investigation and Handling of Production Safety Accidents, and the types and quantities of

hazardous chemicals that reach the stipulations of GB 18218 are major hazard sources; those

that do not reach the above-mentioned stipulations are general hazard sources. In accordance

with the hazard level, general hazard sources are divided into three levels: Level-I, Level-II and

Level-III.

4.6 The electrochemical energy storage stations shall regularly carry out hazard sources

identification. In accordance with the hazard sources identification results, establish and

improve corresponding safety management systems, set up safety signs, and meanwhile, carry

out hazard sources registration, filing, archiving and problem rectification.

4.7 After the renovation and expansion of the electrochemical energy storage stations, or when

the service conditions of the equipment and the environment, in which, the equipment operates,

are significantly changed, hazard sources identification shall be re-conducted.

5 Identification Methods

5.1 The methods of hazard sources identification of electrochemical energy storage stations

include safety checklist method, preliminary hazard analysis method, operating condition

hazard assessment method and analytic hierarchy process method, etc. When the hazard levels

determined by multiple identification methods for the same hazard source are inconsistent, the

higher hazard level shall prevail.

5.2 The safety checklist method is applicable to hazard sources identification during the

operation and accident investigation of electrochemical energy storage stations. By organizing

experts to evaluate various hazardous and harmful factors listed in the safety checklist,

comprehensively determine the hazard level of hazard sources. See Appendix A for details.

5.3 The preliminary hazard analysis method is applicable to hazard sources identification when

electrochemical energy storage stations adopt new technology and come into contact with new

equipment and facilities. By organizing experts to analyze the possibility and severity of various

hazardous and harmful factors listed in the preliminary advance analysis table,

comprehensively determine the hazard level of hazard sources. See Appendix B for details.

5.4 The operating condition hazard assessment method is applicable to hazard sources

identification in all stages of production, such as: operation, overhaul, maintenance and testing

of electrochemical energy storage stations. In accordance with the actual situation in safety

production activities, reasonably determine the possibility of the occurrence of accidents or

hazardous events, the frequency of exposure to hazardous environments and the severity value

of possible consequences after the occurrence of an accident, comprehensively determine the

hazard level of hazard sources. See Appendix C for details.

5.5 The analytic hierarchy process method is applicable to hazard sources identification in the

overhaul and testing of electrochemical energy storage stations. In accordance with the nature

of hazardous and harmful factors of electrochemical energy storage stations, they are divided

into several layers. In accordance with the layers, determine the influencing factors, and

comprehensively determine the hazard level of hazard sources. See Appendix D for details.

6 Identification Content

6.1 Hazard Sources of Equipment and Facilities

v) Insufficient electrical clearance in the hydrogen supply pipeline;

w) The secondary storage tank confirmation is missing and the measures of preventing

the stack from external force impact are missing;

x) The fuel cell shock absorber is missing;

y) The storge of lithium-ion batteries and lead-acid (carbon) battery spare parts does not

comply with the relevant requirements.

6.1.2 Battery management system

The content of hazard sources identification of the battery management system shall mainly

include:

a) Incorrect and loose wiring;

b) The operating environment conditions do not comply with the requirements;

c) System self-diagnosis failure;

d) The fire resistance level of cables does not comply with the requirements;

e) Data collection failure;

f) Communication failure;

g) The alarm content is missing and the protection instructions are not in time;

h) The battery cluster switching, temperature regulation, circulation pump and valve

control do not comply with the requirements;

i) Status estimation is inaccurate;

j) Improper configuration of the equilibrium function;

k) Insulation resistance detection is missing and the error is excessive;

l) Abnormal parameter setting;

m) Abnormal data display;

n) Electrical adaptability does not comply with the requirements;

o) Electromagnetic compatibility, insulation voltage resistance, and moisture and heat

resistance do not comply with the requirements;

p) System availability does not comply with the requirements.

6.1.3 Energy storage converter

The content of hazard sources identification of energy storage converter shall mainly include:

a) Damaged cabinet, loose and broken fasteners, and frequent vibration;

b) The cabinet is not tightly sealed;

c) Incorrect and loose wiring;

d) Failure of ventilation equipment and temperature control system;

e) The converter and cables are overloaded, and heat is generated;

f) The converter has abnormal noise and smell;

g) Insulation damage of power components and partial discharge;

h) Equipment insulation detection failure;

i) Not grounded or improperly grounded;

j) Converter communication failure;

k) Abnormal function of the control system;

l) Improper coordination of protection settings;

m) The electromagnetic compatibility does not comply with the requirements;

n) The measures of preventing cold, moisture and condensation inside the cabinet do not

comply with the requirements;

o) The operating environment conditions of the converter do not match the normal

operating environment conditions of the equipment.

6.1.4 Boosting transformer and high and low voltage cabinet

The content of hazard sources identification of boosting transformer and high and low voltage

cabinet shall mainly include:

a) The transformer and its components are corroded, cracked and poorly sealed;

b) Damage of the transformer bushing;

c) The transformer makes abnormal noise and smell during operation;

d) The transformer core is incorrectly grounded and the grounding current is large;

e) Transformer overload;

f) The transformer is leaking oil, the oil temperature is too high and the oil

e) The current transducer configuration and secondary winding distribution are

unreasonable, and the main protection has a dead zone;

f) Communication failure;

g) Cable overcurrent, cable insulation aging, cable insulation failure and cable insulation

breakdown;

h) Grounding is incorrect, missing or failed;

i) Incorrect and loose wiring;

j) Identification plate is not correctly set;

k) The secondary equipment and facilities supporting the primary equipment are missing.

6.1.6 Monitoring system

The content of hazard sources identification of the monitoring system shall mainly include:

a) The system data collection and alarm classification functions do not comply with the

requirements;

b) The control and regulation functions are incomplete, and cannot satisfy the

requirements for operation and regulation;

c) Improper selection of network structure, communication media, communication

protocols and communication interfaces;

d) Abnormalities in station level equipment, local level equipment, network

communication equipment and monitoring system safety protection equipment;

e) Time synchronization equipment failure;

f) The anti-accidental locking equipment is faulty and has incomplete functions;

g) The selection of DC power supply system battery capacity and AC uninterruptible

power supply capacity does not comply with the requirements for accidental power

outages;

h) Cable overcurrent, cable insulation aging, improper cable insulation and cable

insulation breakdown;

i) Grounding is incorrect, missing or failed;

j) Abnormal self-diagnosis function;

k) The permission settings do not comply with the requirements;

l) Identification plate is not correctly set;

m) The environmental conditions, under which the monitoring system operates, do not

comply with the requirements.

6.1.7 Prefabricated cabin

The content of hazard sources identification of prefabricated cabin shall mainly include:

a) The strength and stiffness of the cabin frame do not comply with the requirements;

b) The connection between the prefabricated cabin and the foundation is unstable, and

the equipment is displaced;

c) The bearing capacity of the foundation does not comply with the requirements, and

the cabin settles;

d) The protection degree of the prefabricated cabin does not comply with the

requirements;

e) The prefabricated cabin is corroded, deformed, peeled off, penetrated, soaked in water

and covered with ice;

f) The sealing, flame retardant and thermal insulation properties of the prefabricated

cabin are not up to standard;

g) Harmful gas leaks in the cabin, and the temperature and humidity do not comply with

the operating requirements;

h) The acid-proof, explosion-proof, fire-proof, water-proof and moisture-proof

measures in the cabin are not in place;

i) Failure of the dynamic environment system, lighting system and auxiliary control

system;

j) The electromagnetic compatibility performance of the auxiliary electrical facilities in

the cabin does not comply with the requirements;

k) Lightning protection of the prefabricated cabin is missing, ground is missing or failed;

l) The fire-proof compartment of power cables and control cables in the cabin does not

comply with the requirements;

m) Measures of preventing small animals are not in place.

6.1.8 Civil structure and HVAC

The content of hazard sources identification of civil structure and HVAC shall mainly include:

e) The alarm signal is not uploaded to the centralized control center;

f) The designed amount of fire-fighting media is insufficient, the parameters of the fire-

fighting system are improperly designed, and fire-fighting materials are not within the

qualified calibration period or are damaged;

g) There is no fixed fire extinguishing device or system in the battery room;

h) Insufficient fire-fighting water source settings;

i) There is no independent backup power supply for the fire-fighting system;

j) The battery room is not equipped with a forced exhaust system, a pressure relief port

or the smoke exhaust system is failed;

k) Failure of the fire-fighting system and exhaust system;

l) There is a lack of linkage between the exhaust system and the combustible gas

detection host;

m) There is a lack of lineage between the fire-fighting system and HVAC, and access

control system, etc.;

n) Explosion-proof equipment is not used for lighting, ventilation, air conditioning and

switches, etc., and the explosion-proof level is insufficient;

o) The cable laying of fire-fighting distribution lines does not satisfy the demands for

continuous power supply in case of fire;

p) In the battery room, the communication and DC cables do not adopt flame retardant

materials;

q) The fire-proof sealing of cable holes is not tight, and the fire resistance level is

insufficient;

r) The fire resistance level of buildings (structures) and fire-proof doors does not comply

with the requirements;

s) The fire-proof distance between buildings (structures) and equipment is insufficient

or the firewall design does not comply with the requirements;

t) The fire-proof distance between the energy storage station and other buildings

(structures) outside the station is insufficient;

u) Improper design of emergency lighting and evacuation signs;

v) The fire-fighting access is blocked or the width does not comply with the

requirements.

6.2 Hazard Sources of Overhaul, Maintenance and Test

6.2.1 Overhaul

The content of hazard sources identification of overhaul shall mainly include:

a) The equipment overhaul cycle and items of the energy storage station do not comply

with the requirements;

b) The enclosure of the external test instruments and equipment is poorly grounded, the

connecting cable is damaged or the insulation is damaged, and the detection time is

not within the required calibration validity period;

c) During the overhaul of components of the energy storage unit, the energy storage unit

is not shut down, anti-static measures are not taken, AC and DC circuit breakers are

not disconnected, and charged energy storage components, such as: capacitors and

reactive resistances, are not fully discharged;

d) During the overhaul of components of the energy storage unit, the location markings

fall off or are unclear, and no measures are taken to prevent accidental entry into

compartments and mis-operation of equipment;

e) When checking the secondary electrical equipment, it is not isolated from the primary

electrical equipment, and instead, sends power to the primary electrical equipment;

f) When the monitoring system software is upgraded or major hardware is replaced, no

measures are taken to prevent mis-operation of equipment, and there are no anti-static

measures;

g) When detecting or replacing components of the fire-fighting system, they are not

effectively isolated from the control system, and the equipment starts incorrectly;

h) When detecting the battery system and energy storage converters, the emergency

shutdown function fails to pass the test or fails during the test;

i) During overhaul operations in the battery cabin, ventilation measures are not strictly

implemented, and the fire-fighting system is not switched to manual control mode;

j) The overhaul personnel do not wear insulating gloves, protective clothing, protective

shoes and other protective articles, and the overhaul tools are not subject to insulation

wrapping;

k) Before overhaul, the AC and DC switches of the primary circuit are not disconnected,

safety warning signs are not hung, and electrical isolation is not performed;

l) During the overhaul of heating equipment, no measures are taken to prevent high-

temperature burns and burns from splashes of high-temperature liquids;

connected to the grounding point in the station or is connected to the grounding point

in the station at multiple points;

d) Before the test, the enclosure of the external test equipment is not effectively

grounded, and no measures are taken to prevent accidental electric shock;

e) The connecting cables of the external test instruments and equipment are not

effectively protected, the cable is damaged or the insulation is damaged;

f) During the test, the anti-accidental locking function of the external test equipment

fails, and no measures are taken to override the anti-accidental locking function;

g) The test setting parameters are entered into the equipment without confirmation, and

no measures are taken to prevent incorrect input of parameters;

h) The newly installed or overhauled hydrogen or liquid storage tanks have not been

tested for air tightness and pressure resistance;

i) The escape route is unclear or blocked, and no measures are taken to ensure the

smoothness of the escape route;

j) When hoisting external test equipment, no measures are taken to prevent the hoist

from accidentally touching live lines;

k) During the test, no measures are taken to prevent computers or networking equipment

without network access certification from accessing the power station network;

l) Before and after the test, the sequence of disconnecting wiring is not standardized;

m) In severe weather, such as: heavy rain, strong wind, heavy fog and heavy snow, the

test environment conditions do not comply with the requirements;

n) After the test is completed, no measures are taken to fully discharge the electric

reactors, capacitors, power modules and other components of the energy storage

converter;

o) The test items do not comply with the relevant technical requirements.

6.3 Hazard Sources of Special Operations

6.3.1 Operation at High Altitudes

The content of hazard sources identification of operation at high altitudes shall mainly include:

a) The operating personnel have not received safety training or professional technical

training;

b) The operating personnel’s safety protective equipment is not fully allocated, and the

safety protective equipment has not passed the inspection;

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