Tentative Rules for Battery Power

RULES FOR CLASSIFICATION OF Ships / High Speed, Light Craft and Naval Surface Craft PART 6 CHAPTER 28 NEWBUILDINGS SPECIAL EQUIPMENT AND SYSTEMS – AD...
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RULES FOR CLASSIFICATION OF

Ships / High Speed, Light Craft and Naval Surface Craft PART 6 CHAPTER 28 NEWBUILDINGS SPECIAL EQUIPMENT AND SYSTEMS – ADDITIONAL CLASS

Tentative Rules for Battery Power JANUARY 2012

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FOREWORD DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and consultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, and carries out research in relation to these functions. The Rules lay down technical and procedural requirements related to obtaining and retaining a Class Certificate. It is used as a contractual document and includes both requirements and acceptance criteria.

© Det Norske Veritas AS January 2012 Any comments may be sent by e-mail to [email protected] For subscription orders or information about subscription terms, please use [email protected] Computer Typesetting (Adobe Frame Maker) by Det Norske Veritas

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Changes – Page 3

CHANGES General This is a new chapter approved by the Executive Committee in November 2011. The rules come into force on 1 July 2012. This chapter is valid until superseded by a revised chapter.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Contents – Page 4

CONTENTS Sec. 1 A. A A A A

General ................................................................................................................................................ 6

Introduction ..................................................................................................................................................................... 6 100 Objective ............................................................................................................................................................... 6 200 Scope..................................................................................................................................................................... 6 300 Application............................................................................................................................................................ 6 400 Relation to other DNV documents........................................................................................................................ 6

B. Terminology and definitions ........................................................................................................................................... 6 B 100 Terminology and definitions................................................................................................................................. 6 C. C C C

Procedural Requirements ................................................................................................................................................ 7 100 Certification requirements .................................................................................................................................... 7 200 Documentation requirements ................................................................................................................................ 7 300 Survey and testing requirements........................................................................................................................... 8

Sec. 2

Design Principles for Battery Power Notation .............................................................................. 9

A. Design Principles ............................................................................................................................................................ 9 A 100 General.................................................................................................................................................................. 9

Sec. 3 A. A A A

Arrangement and System Design.................................................................................................... 10

Design of Battery Spaces .............................................................................................................................................. 10 100 Operational environment control ........................................................................................................................ 10 200 Safety ................................................................................................................................................................. 10 300 Hazardous Areas ................................................................................................................................................. 10

Sec. 4

Batteries............................................................................................................................................. 11

A. General .......................................................................................................................................................................... 11 A 100 Flame-retardant ................................................................................................................................................... 11 B. Lithium Batteries........................................................................................................................................................... 11 B 100 Safety .................................................................................................................................................................. 11 C. Lead Acid and NiCd Batteries ...................................................................................................................................... 11 C 100 General................................................................................................................................................................ 11 D. Other Battery Technologies .......................................................................................................................................... 11 D 100 General................................................................................................................................................................ 11 E. Installation..................................................................................................................................................................... 11 E 100 Materials and signboards .................................................................................................................................... 11 E 200 Ingress protection................................................................................................................................................ 11 F. Inspection and Testing .................................................................................................................................................. 11 F 100 General................................................................................................................................................................ 11

Sec. 5

Fire Safety ......................................................................................................................................... 13

A. General .......................................................................................................................................................................... 13 A 100 Fire Safety........................................................................................................................................................... 13

Sec. 6

Electrical Systems............................................................................................................................. 14

A. General .......................................................................................................................................................................... 14 A 100 General................................................................................................................................................................ 14 B. Power Converters .......................................................................................................................................................... 14 B 100 General................................................................................................................................................................ 14 B 200 Battery charger.................................................................................................................................................... 14

Sec. 7

Control, Monitoring and Safety Systems ....................................................................................... 15

A. General .......................................................................................................................................................................... 15 A 100 General................................................................................................................................................................ 15 B. Control and Monitoring ................................................................................................................................................ 15 B 100 Battery Management System ............................................................................................................................. 15 B 200 Energy Management System, EMS (only applicable for Battery Power) .......................................................... 15

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Contents – Page 5

C. Alarm ............................................................................................................................................................................ 15 C 100 Battery alarms ..................................................................................................................................................... 15 D. Safety ........................................................................................................................................................................... 16 D 100 Safety functions .................................................................................................................................................. 16

Sec. 8

Installation ........................................................................................................................................ 17

A. Inspection and Testing .................................................................................................................................................. 17 A 100 Inspection............................................................................................................................................................ 17 A 200 Testing ................................................................................................................................................................ 17

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.1 – Page 6

SECTION 1 GENERAL A. Introduction A 100 Objective 101 The rules in this chapter give requirements to battery installations in vessels (both for propulsion and other services). 102

The rules in this chapter are introduced as tentative rules as defined in Pt.1 Ch.1 Sec.1 A200.

A 200 Scope 201

The requirements cover:

— battery systems used for propulsion. — safety requirements for batteries of other technologies than NiCd and Lead Acid batteries are covered by this chapter. — requirements for certification of the batteries. 202

The rules are applicable for installations with a variety of battery chemistry. Guidance note: Typical batteries that may be relevant are Lead Acid, NiCd and Lithium Ion batteries of different electrochemistry and designs. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

203 Since the battery technology is under development the requirements of this rule chapter may have to be supported by additional considerations and requirements from case to case. Designs which are not in compliance with this rule chapter may be approved after evaluation by the classification society if they are found to have an equivalent level of safety. A 300 Application 301 Vessels where the battery power is used as propulsion power during normal operation shall satisfy the requirements in this rule chapter and will be given class notation Battery Power. A 400 Relation to other DNV documents 401

Electrical installations is in general described in Pt.4 Ch.8.

402

Control and Monitoring Systems is in general described in Pt.4 Ch.9.

403

Fire Safety is in general described in Pt.4 Ch.10.

B. Terminology and definitions B 100 Terminology and definitions 101 BMS: Battery Management System, a collective terminology comprising control, monitoring and protective functions of the battery system. 102

EMS: Energy Management System, a system providing monitoring and control of the energy capacities.

103

Battery cell: The smallest building block in a battery.

104

Battery string: A battery string comprises a number of cells connected in series.

105

Battery bank: A battery bank comprises of one or number of battery strings connected in parallel.

106

Battery space: A limited area where the batteries are installed (this may be a battery room).

107 Battery System: The whole battery installation including battery banks, electrical interconnections, BMS and other safety features. 108

Propulsion power: The power needed for propulsion or a part of the propulsion of the vessel.

109

Standby power: The power needed for a period as an alternative to the main power generations, e.g. UPS.

110

Starting power: The power needed for a short period for starting of machinery.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.1 – Page 7

111 SOC: State of Charge in percentage of the rated capacity available for the discharge of the battery (“Fuel gauge”). 112 SOH: The State of Health reflects the general condition of a battery and its ability to deliver the specified performance compared with a new battery.

C. Procedural Requirements C 100 Certification requirements 101 Battery system shall be certified and tested at manufacturer. Testing shall be performed in accordance with an approved test programme. 102 103

Batteries used for the notation Battery Power shall be certified. Batteries that are not covered by Pt.4 Ch.8 and larger than 50 kVAh shall be certified. Guidance note: Batteries covered by Pt.4 Ch.8 are Lead Acid and NiCd batteries. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

104

The BMS shall be certified according to Pt.4 Ch.9 as a part of the battery system.

105

Other electrical components shall be certified as outlined in Pt.4 Ch.8 Sec.1 Table B3.

C 200 Documentation requirements 201 Documentation related to system design shall be submitted as required by Table C1 and C2 (Battery Power notation). Table C1 System design, documentation requirements for main class Object Documentation type Additional description Z030 – Arrangement plan Safety assessment including internal and external G010 – Risk analysis safety risks (see Sec.3 A200). Z140 – Test procedures for quay Inspection and test plan onboard, see Sec.8 and sea trial. Z160 – Operation plan See C205 Z180 – Maintenance plan See C206 Main battery rooms If required based on the safety assessment. Including: G090 – Area safety chart

G080 – Hazardous area classification drawing Fire extinguishing – Fixed fire extinguish systems in machinery G200 system documentation spaces, fixed Electric power system

Main battery power system

E170 – Electrical Schematic drawing E170 – Electrical schematic drawing I030 – Block diagram

— structural fire protection — fire and gas detection — fire extinguishing — ventilation If required based on the safety assessment. Zones as defined by IEC 60079-10. Battery rooms. If required based on the safety assessment. Schematic drawing of the battery system showing the internal arrangement of the battery banks, strings and cells, including switchgear and control gear. Only applicable for Lithium Batteries larger than 50 kVAh. Emergency stop for battery system, including location of emergency stop. Only applicable for Lithium Batteries Interfaces with chargers, power and energy management systems and alarms.

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Info FI AP AP FI FI

AP

AP AP

AP

AP

FI

Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.1 – Page 8

Table C2 System design, additional documentation requirements for class notation Battery Power Object Documentation type Additional description An overall description of the propulsion and power installation and operating philosophy for all E220 – System philosophy. relevant operating modes, including charging. This document must be submitted prior to commencing approval work. Electric power Load balance (energy and power) including size of system batteries, charger capacity and discharge/recharge E040 – Electrical power capacity. consumption balance The load balance shall reflect the operational mode stated in the system philosophy. Maximum designed deterioration rate shall be reflected. Power management I020 – Control system functional Functional description of the energy management system description system (EMS).

Info FI

AP

FI

202 Equipment required to be delivered with DNV Product Certificate shall be documented as described in Table C3. Other electrical equipment may require a DNV Product Certificate, see Pt.4 Ch.8 Sec.1 Table B3. Table C3 Component certification, documentation requirements Object Documentation type Additional description Z072 – Safety description Ref Sec.4 Z100 – Specification Including ratings and environmental data. Z120 – Test procedure at Ref Sec.4 Battery manufacturer. I200 – Control and monitoring Battery management system (BMS), control, system documentation monitoring and protective functions.

Info FI AP AP AP

203

For general requirements to documentation, including definition of the Info codes, see Pt.0 Ch.3 Sec.1.

204

For a full definition of the documentation types, see Pt.0 Ch.3 Sec.2.

205

An operation manual for the battery system shall be kept onboard and shall include:

— — — —

charging procedure normal operation procedures of the battery system emergency operation procedures of the battery system estimated battery deterioration (ageing) rate curves.

206 A plan for systematic maintenance and function testing shall be kept onboard showing in detail how components and systems shall be tested and what shall be observed during the tests. Columns showing test dates and verification of tests carried out shall be included. The plan shall include: — For vessels with notation Battery Power estimated SOH (rest lifetime of the batteries). — All instrumentation, automation and control systems affecting the battery system. — Test intervals to reflect the consequences of failure involving a particular system. Functional testing of critical alarms should not exceed 3 month intervals. For non-critical alarms, the longest intervals are normally not to surpass 12 months. Guidance note: For vessels with class notation E0, this information should be included in the required plan for periodical testing. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

207 Special components, equipment or systems not covered in the different parts of the existing rules may be required to be documented. Documentation requirements for such components and equipment will be subject to special consideration. C 300 Survey and testing requirements 301

Requirements to newbuilding survey can be found in to Sec.8.

302

Requirements to survey of the batteries at manufacturers can be found in Sec.4 F.

303 Survey requirements for vessels in operation with class notation Battery Power can be found in the Rules for Classification of Ships, Pt.7 Ch.1 Sec.2.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.2 – Page 9

SECTION 2 DESIGN PRINCIPLES FOR BATTERY POWER NOTATION A. Design Principles A 100 General 101 The design shall ensure that any single failure in the battery system shall not render any main functions unavailable for more than max restoration time specified in Pt.4 Ch.1 (Redundancy type R1). Guidance note: Main functions are defined in the Rules for Classification of Ships, Pt.1 Ch.1 Sec.1. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

102 The arrangement of the battery spaces must be so that a hazardous situation that may be caused by a break down of the batteries (e.g. gassing, explosion, fire) can not lead to loss of propulsion or auxiliary power for essential or important users. 103 When a battery system is regarded as a main source of power (replaces one of the required main source of power in Pt.4 Ch.8 Sec.2 B101 b), it shall be located in the machinery space. A battery space contiguous to the machinery space may be considered. 104

A battery system shall consist of at least two parallel battery strings with separate short circuit protection.

105 When a battery system is regarded as main source of power (replaces one of the required main source of power in Pt.4 Ch.8 Sec 2 B101 b)), then the capacity of the battery shall be sufficient for the intended operation of the vessel. The design capacity shall be stated in the appendix of the class certificate as an operational limitation. Guidance note: - Before leaving port the battery capacity to be verified sufficient for the planned voyage. The required minimum capacity is an operational issue. - The capacity deterioration (ageing) rate for the battery to be documented, considering actual modes of operation. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

106

Energy Management System (EMS) shall be installed.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.3 – Page 10

SECTION 3 ARRANGEMENT AND SYSTEM DESIGN A. Design of Battery Spaces A 100 Operational environment control 101 Unless the battery is designed for the environmental conditions given in Pt.4 Ch.8 Sec.3 B the battery must be installed within an environmentally controlled space. A 200 Safety 201

For Lead Acid batteries and NiCd the requirements in Pt.4 Ch.8 Sec.2 I400 applies.

202 The arrangement of the battery spaces must be such that the safety of passengers, crew and vessel is ensured. This shall be documented by a Safety Assessment with the following steps: a) identification of hazards (a list of all relevant accident scenarios with potential causes and outcomes); b) assessment of risks (evaluation of risk factors); c) risk control options (devising measures to control and reduce the identified risks); d) actions to be implemented Guidance note: The risk assessment shall cover all potential hazards represented by the type (chemistry) of battery and at least cover: - potential gas development (toxic, flammable, corrosive) - fire risk - explosion risk - necessary detection and alarm systems (gas detection, fire detection etc) and ventilation - for battery chemistry that may have potential for thermal runaway, a suitable fire extinguish system must be installed (the type of extinguishing medium is different for e.g. LiPolymer, LiFePO4 and Li(NiCoAl)O2). ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

203 External hazards, such as water ingress, fire, pipe leakages etc shall be taken into account in the safety assessment. A 300 Hazardous Areas 301 Depending on the chemistry of the batteries it may be needed to class the areas, where flammable gas may arise, according to the zones definitions given in IEC 60079-10. This classification shall be used as a basis to support the proper selection and installation of equipment for use in the hazardous area. The hazardous area plan shall be a part of the complete hazardous plan for the vessel. 302 If explosion protected equipment (Ex equipment) is needed then the installation requirements in Pt.4 Ch.8 Sec.11 is applicable.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.4 – Page 11

SECTION 4 BATTERIES A. General A 100 Flame-retardant 101

The battery casing shall be made of a flame-retardant material.

B. Lithium Batteries B 100 Safety 101 All hazards shall be described in a safety description. Safety precautions mitigating the identified risks may be required. 102 The batteries shall have an integrated Battery Management System (BMS). This system shall control the charging and equalizing of the cell voltage. See Sec.7 for details. 103

The battery charging equipment shall interface with and be controlled by the BMS.

104 Battery systems larger than 50 kVAh shall be equipped with an independent emergency shutdown for isolation of the battery. 105 For sealed batteries, a safety pressure valve or other means of explosion protection (weak point) is to be included in the battery design. 106 For battery chemistry that may release hazardous gasses in case of ruptures, an exhaust ventilation duct shall be considered. 107 For battery chemistry that may have potential for thermal runaway, a suitable fire extinguish system must be installed.

C. Lead Acid and NiCd Batteries C 100 General 101

Requirement in Pt.4 Ch.8 applies.

D. Other Battery Technologies D 100 General 101

Other battery technologies may be used. It will be considered on a case by case basis.

E. Installation E 100 Materials and signboards 101

Relevant parts of Pt.4 Ch.8 Sec.10 B302 and B304 applies.

E 200 Ingress protection 201

The IP rating of the batteries depends on the location. As a minimum the following applies:

— IP2X for low voltage (< 1500 Vdc) installations — IP32 for high voltage (> 1500 Vdc) installations.

F. Inspection and Testing F 100 General 101

A test program for functional and safety tests at manufacturer shall be submitted for approval before testing.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.4 – Page 12

Guidance note: Lead Acid: The IEC 60896-11 and IEC 60896-21 standards are applicable for respectively vented and valve regulated batteries. NiCd: The IEC 60623 and IEC 62259 standards are applicable for respectively vented and valve regulated batteries. Lithium: The IEC 62620 and 62619 draft standards may be relevant for respectively functional tests and safety tests. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.5 – Page 13

SECTION 5 FIRE SAFETY A. General A 100 Fire Safety 101 Where the Government of the flag state have not authorized the Society to issue the SOLAS Safety Certificates on their behalf, the Society will only require either written confirmation from the Flag State that the SOLAS certificate will be issued by them or a copy of the SOLAS Certificate to be submitted for DNV files. Based on this, the vessel will be assigned Main Class. 102 Where the Government of the flag state have authorized the Society to issue the SOLAS Safety Certificates on their behalf, the Society will give effect to the fire protection, detection and extinction requirements of Ch.II-2 of SOLAS. Guidance note: Battery spaces used for propulsion (Battery Power notation), shall be regarded as “other machinery spaces”. For batteries used as start power or standby power then the battery space is either “service space (low risk/high risk)”, “Other machinery spaces” or “Cargo spaces”. This is depending on the amount of combustible material available in the space and the battery application. The arrangement of fire fighting systems in battery spaces, and the type of extinguishing medium shall be evaluated based on the actual battery chemistry/Safety assessment (ref Sec.3 A202). ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.6 – Page 14

SECTION 6 ELECTRICAL SYSTEMS A. General A 100 General 101

The requirements in this chapter are additional to those given in Pt.4 Ch.8.

102 The outgoing circuits on a battery system shall in addition to short circuit and over current protection be provided with a switch disconnector for isolating purposes so that isolating for maintenance is possible. 103 A battery system shall be able to supply the short circuit current necessary to obtain selective tripping of downstream circuit breakers and fuses. For Battery Power notation the duration of the short circuit current from the battery system shall be at least 2 seconds.

B. Power Converters B 100 General 101

Requirements to semi conductor converters are given in Pt.4 Ch.8 Sec.7.

B 200 Battery charger 201

The charger shall communicate with the battery management system.

202

The charger shall be designed with the needed capacity specified by the battery application.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.7 – Page 15

SECTION 7 CONTROL, MONITORING AND SAFETY SYSTEMS A. General A 100 General 101 For instrumentation and automation, including computer based control and monitoring, the requirements in this chapter are additional to those given in Pt.4 Ch.9.

B. Control and Monitoring B 100 Battery Management System 101

The BMS shall control:

— internal charging/discharging of the battery — battery temperature — cell balancing. 102 The following parameters shall be measured and indicated at local control panels or in remote workstations — — — — —

cell voltage cell temperature battery string current ambient temperature electrical insulation resistance.

B 200 Energy Management System, EMS (only applicable for Battery Power) 201 The following parameters shall be provided with remote monitoring at all control stations (engine control room/navigating bridge): — remaining capacity of batteries (SOC). For calculation of SOC, SOH (State of Health) shall be considered. — direction of the energy flow in the battery (charging or discharging).

C. Alarm C 100 Battery alarms 101 Any abnormal condition in the battery plant shall initiate an alarm in the vessel’s main alarm system with individual or group-wise indication. For vessels without a centralised main alarm system, battery alarms shall be presented in a continuously manned location. 102 Abnormal conditions which can develop into safety hazards shall be alarmed before reaching the hazardous level. Sensors and other components used for such alarms shall be separate from emergency shutdown or other protective safety functions. 103

Battery failure shall give an alarm.

104

Tripping of battery breakers shall give alarm.

105

High cell temperature shall give alarm.

106

High ambient temperature in battery space shall give alarm.

107 For Battery Power notation an individual alarm shall be given at the control stations when SOC reaches minimum required capacity as required for intended operation of the vessel. 108

For Battery Power notation then shutdown of the battery or part of the battery shall give alarm. Guidance note: Possible other abnormal conditions to be alarmed are tripping of protection, possible gas detection, smoke detection, heat detection, over current, temperature, ventilation, over voltage, under voltage (discharge), cell temperature, voltage unbalance between battery cells, charging failure, high cell pressure or opening of cell safety vent or venting mechanism. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.7 – Page 16

D. Safety D 100 Safety functions 101

Activation of protective safety functions shall give alarm.

102

The emergency shutdown of the battery system shall be arranged at the following locations:

— navigation bridge (for Battery Power class notation) — adjacent to (outside of) the battery space. 103 Emergency shutdown shall be arranged as hardwired circuit and separated from cables used for control, monitoring and alarm functions. Guidance note: Requirements in Pt.4 Ch.8 Sec.2 H500 are applicable. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

104 Battery protection shall be arranged for excessive temperatures in the batteries. This protection shall be arranged fail-safe and with components independent from those used for the required temperature indication, alarm and control functions. Guidance note: Fail-safe is defined as bringing the batteries to a safe state. ---e-n-d---of---G-u-i-d-a-n-c-e---n-o-t-e---

105 Other fail-safe and independent protective functions shall be implemented if the battery type or design used comprises additional hazards.

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Rules for Ships / High Speed, Light Craft and Naval Surface Craft, January 2012 Pt.6 Ch.28 Sec.8 – Page 17

SECTION 8 INSTALLATION A. Inspection and Testing A 100 Inspection 101

Check the design of the battery space and all of the safety features.

A 200 Testing 201 — — — — —

A test plan for the installation onboard the vessel shall be submitted for approval. This plan shall include: functional tests including dynamic responses charging and discharging capacities. correct interface between the charger and the battery. test of alarms and safety functions. test of functions in the battery space (possible ventilation, liquid cooling, gas detection, fire detection, leakage detection etc) as installed.

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