Product Overview

Summary: This Battery Storage System Safe Operating Procedure provides a clear, step‑by‑step framework for safely installing, operating, and maintaining stationary battery energy storage systems in Australian workplaces. It helps businesses manage electrical, fire, and chemical hazards while demonstrating compliance with WHS duties and relevant Australian Standards.

Battery energy storage systems (BESS), including lithium‑ion and other chemistries, are rapidly being deployed across commercial, industrial and strata sites to manage energy use and support solar installations. While these systems deliver significant operational and cost benefits, they also introduce complex risks such as electrical shock, arc flash, thermal runaway, fire, explosion, and hazardous gas release. This Safe Operating Procedure provides a practical, WHS‑aligned method for controlling those risks throughout the full lifecycle of the system – from delivery and installation through to routine operation, inspection, maintenance, and decommissioning.

Developed for Australian conditions and regulatory expectations, the SOP sets out clear roles and responsibilities, pre‑start checks, isolation and lock‑out requirements, environmental and ventilation considerations, and emergency response actions tailored to battery incidents. It supports PCBUs to meet their primary duty of care under WHS legislation, while giving workers simple, repeatable instructions that can be used for training, toolbox talks and contractor management. By implementing this procedure, organisations can confidently integrate battery storage into their operations, protect people and property, and reduce the likelihood of costly downtime, regulatory scrutiny, or reputational damage following an incident.

Key Benefits

• Ensure safe installation, operation and maintenance of battery storage systems in line with Australian WHS obligations.
• Reduce the risk of fires, explosions and thermal runaway events through structured hazard identification and control measures.
• Standardise how workers, contractors and emergency wardens interact with the battery system, improving consistency and competence.
• Demonstrate due diligence to regulators, clients and insurers with a documented, defensible procedure for battery storage safety.
• Minimise unplanned downtime and asset damage by embedding robust inspection, monitoring and fault‑response processes.

Who is this for?

• Electrical Contractors
• Solar and Battery Installers
• Facilities Managers
• WHS Managers and Advisors
• Operations Managers
• Maintenance Technicians
• Site Supervisors
• Asset and Energy Managers
• Emergency Wardens
• Project Managers – Renewable Energy Installations

Hazards Addressed

• Electric shock and arc flash during installation, commissioning, testing and maintenance
• Thermal runaway leading to fire, explosion or rapid release of energy
• Release of toxic or flammable gases and vapours from batteries or associated equipment
• Fire spread to adjacent structures, equipment or stored materials
• Short circuits and overcurrent faults caused by incorrect connections or damaged cabling
• Exposure to corrosive electrolyte or battery chemicals during damage or failure
• Burns from hot battery surfaces, terminals or conductors
• Manual handling injuries during delivery, installation and replacement of battery units
• Confined space and ventilation risks in battery rooms or enclosures
• Environmental contamination from spills, leaks or improper disposal of batteries and components

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and System Overview
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 System Description and Location of Key Components
• 6.0 Hazard Identification and Risk Controls for Battery Storage Systems
• 7.0 Required Personal Protective Equipment (PPE) and Safety Equipment
• 8.0 Pre‑Installation and Delivery Requirements
• 9.0 Installation and Commissioning Procedure (Licensed Electrician Only)
• 10.0 Normal Operation and Monitoring Procedure
• 11.0 Inspection, Testing and Preventive Maintenance
• 12.0 Isolation, Lock‑Out/Tag‑Out and De‑energisation Steps
• 13.0 Managing Faults, Alarms and Abnormal Conditions
• 14.0 Emergency Response – Fire, Thermal Runaway and Gas Release
• 15.0 Spill, Leak and Contamination Management
• 16.0 Manual Handling and Storage of Batteries
• 17.0 Contractor Management and Site Access Controls
• 18.0 Environmental Management and Waste Disposal of Batteries
• 19.0 Training, Induction and Competency Records
• 20.0 Documentation, Review and Continuous Improvement

Legislation & References

• WHS Act and WHS Regulations as implemented in relevant Australian states and territories
• Safe Work Australia – Managing electrical risks in the workplace: Code of Practice
• AS/NZS 5139: Electrical installations – Safety of battery systems for use with power conversion equipment
• AS/NZS 3000: Electrical installations (Australian/New Zealand Wiring Rules)
• AS 4086.2: Secondary batteries for use with stand‑alone power systems – Installation and maintenance
• AS 2676.2: Guide to the installation, maintenance, testing and replacement of secondary batteries in buildings – Sealed cells
• AS 1851: Routine service of fire protection systems and equipment
• AS 3745: Planning for emergencies in facilities
• Safe Work Australia – Managing risks of hazardous chemicals in the workplace: Code of Practice