Risk Assessment / JSA and Risk Management

Risk Assessment / JSA

Battery Arc Flash Calculator

This tool is used to calculate the potential arc flash hazard of a battery, and therefore the level of PPE required when working on it. 

The arc flash incident energy for battery systems is calculated by:

IE_m = 0.01 x V_sys x I_arc x (T_arc/D²) x MF

 

Battery mounted in enclosure?

Only select this box if the battery is mounted in a separate enclosure (box).  This increases the Multiplying Factor to 3.

For battery rooms = 1.5

Multiplying factor 

An enclosure or box can mean that the amount of energy dissipated in the direction of the person working on the battery could be increased. The factor by which this is increased is known as the multiplying factor. 

For battery system enclosures and BESS enclosures, a minimum multiplying factor of 3 is applied. For battery rooms, a minimum multiplying factor of 1.5 is applied.

Battery intra-string protection installed?

Common scenarios: lead acid battery banks with a fuse installed within the string (before the terminals). 

Protection device I_trip value

This is the I_trip rating of the intra-string fuse. This value is considerably higher than the nominal current of the fuse. Consult manufacturer's specifications. 

 

Unprotected battery fault current / prospective fault current - I_bf 

The prospective fault current (prospective short circuit current) at the battery terminals of the battery system. This information should be provided by the battery manufacturer.

The I_bf is usually greater than the nominal current rating of a fuse/CB integrated in the battery system.

For lead acid battery banks, this is the battery voltage divided by the internal resistance - check the manufacturer's specifications. 

Arc Flash

Electrical explosion or discharge, which occurs between electrified conductors during a fault or short circuit condition

Arc flash incident energy - IE_m

Measurement applied to determine the available incident arc flash energy at a specified distance originating from an arc flash. 

Arc flash protection boundary

Boundary marked by the distance from electrical equipment as which the arc flash incident energy is equal to 1.2 cal/cm2. This is used to define where PPE may be required. 

Arcing time - T_arc

For work being undertaken on the PCE side of the battery system's protection device, the operating time for the protection based on the prospective fault current shall be used as the arcing time. 

If the operational time of the protective device is unknown, an arcing time of 2 seconds should be used.

Working distance - D

A maximum working distance of 45cm is used. 

Arcing current - I_arc

Calculated at 0.5 x I_bf  (battery prospective fault current, in amps. )

Risk Management

The Risk Manager in SolarPlus helps you assess potential risks associated with system installations as part of your proposal.

To access the Risk Manager, click on the Install section on the right side of your screen, and select Risk Manager.

After selecting the Risk Manager icon, you will be redirected to the Risk Manager page. This page includes various safety considerations, organized into six key categories:

• Battery Arc Flash Calculator – Assesses potential arc flash hazards in battery systems.
• Job Safety Information – Provides essential safety details for the installation process.
• Solar Risk Assessment – Evaluates risks specific to solar system installations.
• Battery Risk Assessment – Identifies potential hazards related to battery setups.
• Pack Up Assessment – Ensures safe procedures when wrapping up the job.
• Additional Site-Specific Hazards & Risk Management – Allows for the identification and mitigation of any unique risks at the installation site.

What is the Battery Arc Flash Calculator?

The Battery Arc Flash Calculator is a tool used to assess potential arc flash hazards in battery systems. Arc flashes occur when a short circuit causes a sudden, high-energy electrical discharge, which can result in extreme heat, pressure, and light, posing risks to both personnel and equipment.

How Does It Work?

The calculator evaluates the risk by analyzing key electrical parameters, such as:

• Unprotected battery fault current – The potential fault current from the battery.
• Battery voltage – The operating voltage of the battery system (e.g., 900V).
• Number of strings – The total number of connected battery strings (e.g., 2).
• Arc flash boundary – The distance within which a worker may be exposed to hazardous energy (e.g., 0.00 cm).
• Arc flash incident energy – The energy released during an arc flash event (e.g., 0.00 cal/cm²).
• l arc & t arc – The arc current and duration affecting energy release (e.g., 0A, 2s).
• Multiplying factor – A scaling factor for energy calculations (e.g., 3).

Safety Implications & PPE Requirements

Based on the calculated incident energy and arc flash boundary, the calculator determines the consequence level and recommends the appropriate Personal Protective Equipment (PPE).

Job Safety Information

The Job Safe Work Method Statement (SWMS) Manager in SolarPlus outlines safety measures for installing solar panels and battery banks. It covers:

• Working at heights – Proper use of harnesses and fall protection.
• Power tools – Safe handling and operation procedures.
• Electrical installation – Ensuring compliance with electrical safety standards.
• Solar panel & battery installation – Secure mounting and connection practices.

Responsibilities & Compliance

• All workers involved must be informed of the SWMS before work begins.
• Daily Toolbox Talks help identify and manage additional site hazards.
• Work must stop immediately if an incident or near miss occurs. The SWMS must be updated, approved, and communicated before resuming.
• Records of SWMS must be kept for the duration of the job or two years if a notifiable incident occurs, per WHS legislation.

Risk Assessment Matrix

The Risk Assessment Matrix in SolarPlus helps assess hazards by evaluating the likelihood and consequences of risks.

Risk Levels & Actions

Hierarchy of Controls

The most effective way to manage risks follows a structured approach:

1. Elimination – Remove the hazard completely.
2. Substitution – Replace with a safer alternative.
3. Isolation – Separate people from the hazard.
4. Engineering Controls – Modify equipment or processes for safety.
5. Administrative Controls – Implement safety procedures and training.
6. Personal Protective Equipment (PPE) – The last line of defense against hazards.

Personal Protective Equipment (PPE) Requirements

All PPE must meet Australian Standards and be inspected regularly. Required PPE includes:

• Foot protection (safety boots)
• Ear protection (earplugs/muffs)
• High visibility clothing
• Head protection (hard hats)
• Eye protection (safety glasses/goggles)
• Face protection (shields/masks)
• Hand protection (gloves)
• Protective clothing (flame-resistant, long-sleeved)
• Breathing protection (respirators)
• Sun protection (hats, sunscreen)
• Fall arrest (harnesses and safety lanyards)

Important Safety Notes

• No loose clothing, jewelry, or untied hair should be worn near machines.
• Always inspect PPE and replace when necessary.

Solar Risk Assessment

This section outlines critical safety measures for solar installation teams to prevent injuries, property damage, and environmental incidents. It categorizes hazards by severity and provides control measures to mitigate risks.

Key Focus Areas:

• General Site Safety: Ensures safe property access, hazard identification, and risk management.
• Working at Heights: Addresses fall prevention, trip hazards, weather risks, and safe ladder use.
• Electrical & Live Part Hazards: Highlights procedures for working near energized equipment to prevent electrocution.

This section provides essential safety guidelines for solar installation teams to minimize risks and ensure a secure work environment. It outlines potential hazards, their severity, and control measures to protect workers, property, and the public. By following these protocols, teams can comply with safety regulations and maintain a safe and efficient installation process.

Battery Risk Assessment

This section evaluates potential hazards related to battery operation, installation, and maintenance, ensuring safety in normal and fault conditions.

Purpose:

• To prevent electrical, fire, chemical, and mechanical hazards in battery systems.
• To define safety controls for normal operation, faults, and emergency situations.
• To ensure compliance with industry safety standards.

Key Areas Covered:

1. Normal Operation Risks:

   • Maintaining safe temperature, voltage, and charging conditions.
   • Preventing hazards like overcharging and overheating.

2. Abnormal Operation & Fault Protection:

   • Addressing risks from overvoltage, overcurrent, arc flash, and electrical faults.
   • Ensuring protection devices function correctly and allow safe shutdown.

3. Fire, Explosion & Environmental Protection:

   • Containing fire risks within battery modules.
   • Protecting against surges, radiation, and transient voltage spikes.

4. Constructional & Mechanical Safety:

   • Ensuring impact-resistant enclosures, proper cable protection, and stable installation.
   • Protecting users from moving parts and mechanical failures.

5. Marking, Instructions & Compliance:

   • Ensuring manufacturer labels, proper installation instructions, and user guidance are provided.

6. Miscellaneous Safety Requirements:

   • Preventing hazards from liquid spills affecting insulation.
   • Ensuring installation locations minimize environmental risks.

7. Chemical Hazards (Battery Chemistry):

   • Managing toxic fume risks, especially with lithium-ion batteries.
   • Ensuring proper ventilation as per manufacturer guidelines.

Pack Up Assessment

The Pack Up Assessment section outlines the necessary steps to ensure a safe and clean worksite after completing solar installation tasks. It focuses on three key areas:

1. Site Clean-Up: Prevents slips, trips, and falls by ensuring tools, waste, and roof debris are removed.
2. Electrical Safety: Reduces the risk of electrical hazards by requiring proper disconnection and inspection of power tools and leads before packing up.
3. Public Safety: Ensures that barricades and safety measures are adjusted or removed appropriately, with supervisor approval, to maintain public safety.

Purpose:
This section is designed to minimize residual hazards after work is completed, ensuring the site is left in a safe, orderly condition for both workers and the public. It reinforces best practices for handling equipment and maintaining safety compliance at the end of the job.

Additional site-specific hazards and risk management steps

You can specify any additional required equipment in this section, including rescue equipment and personnel trained in rescue or first aid. Additionally, update the Site Address on the Site Energy page to ensure accurate hospital location information.

After reviewing all the information, select a user to sign off on the Risk Management Assessment. Once you have confirmed that all hazards are properly controlled and the job can be completed safely, click "Yes, Proceed with Job."

Once the Risk Assessment has been reviewed and signed off, you can download the PDF by scrolling to the top and clicking the Download PDF icon.