Attachment 3 LBSP SDP.pdf

Date: YYYY/MM/DD Revision #:

Lithium Battery Safety Certification Program (LBSP)

Safety Data Package

1. BACKGROUND: NAVSEAINST 9310.1C requires all Navy and Marine Corps activities to obtain lithium battery safety certification for all lithium batteries prior to use or transport on Navy facilities, ships and aircrafts, regardless of source. Material to which this instruction applies includes all primary (non-rechargeable) and secondary (rechargeable), active, thermal and reserve lithium batteries, and all equipment powered by lithium electrochemical power sources.

The lithium battery safety certification process is defined by NAVSEA Technical Publication S9310-AQ-SAF-010 Rev 3 of 3 Nov 2020. Exceptions to testing, review and certification requirements, and best practices are discussed in S9310.

2. PURPOSE. The purpose of the safety data package is to provide the LBSP Technical Agents the relevant technical and safety information for the battery cell, battery pack, and system to support a safety evaluation of the lithium battery. Additional information required are: concept of operations (CONOPS), stowage and use logistics, and sparing plan. For systems going aboard Naval ships and submarines for transportation and/or deployment, specific ship’s integration information is required to support NAVSEA 05 technical reviews. This safety evaluation is a system-of-system safety review; therefore, it is important to understand the environment and condition in which the battery is used to assess the impact to the facility, platform (s) and neighboring systems. This SDP shall be submitted as an enclosure to the lithium battery safety certification request letter. (Words in italics are to be modified or deleted).

3. BATTERY COMPONENT CELL AND BATTERY PACK DESIGN DATA.

a. Battery Component Cell (Single Cell) Design Data.

i. Manufacturer. Name, address, phone number.

ii. Model number and/or part number.

iii. Electrical description. Voltage, ampere-hour capacity, and nominal load profile.

iv. Electrical safety devices integral to the battery cell.

v. Battery cell format/configuration. Cylindrical, prismatic, pouch, A, AA, AAA, C, D, etc…including the dimension of the battery.

vi. Cell yield pressure.

vii. Cell failure modes. Indicate whether a single cell failure can cascade into multiple cell failures based on historical test data or equivalent.

viii. All applicable Safety Data Sheets (SDSs), product information sheets or equivalent document.

b. Battery Pack Design (Multiple Cells) Data.

i. Manufacturer. Name, address, phone number.

ii. Model number and/or part number.

iii. Electrical description. Voltage, ampere-hour capacity, and nominal load profile.

iv. Electrical safety devices integral to the battery pack.

v. Battery pack configuration. Number of cells in the battery pack; indicate the battery pack electrical connections, parallel or series.

vi. Battery housing/container, strength, and free volume. Use section 4.e if provided at the system level.

vii. Battery pack yield pressure and battery pack pressure relief or venting mechanisms. If unvented, indicate the battery housing ambient yield pressure.

Use section 4.f if provided at the system level.

viii. Discharge ratings.

ix. All applicable Safety Data Sheets (SDSs), product information sheets or equivalent document.

c. For Secondary (Rechargeable) Batteries Only.

i. Rated cycle-life and the mean-time-between failures for the battery cell and the battery pack.

ii. Discharge and charge rates, including the limiting discharge and charge rates.

d. For Thermal Batteries Only.

i. Case temperature information, to include:

1. Specification requirements and actual battery performance.

2. Complete temperature profile from activation to battery cool down.

This is normally beyond specification life.

ii. Method of activation, and sequence/failure analysis.

iii. Battery cool down time.

iv. Hang-fire analysis.

e. For Reserve Batteries Only.

i. Method of activation, and sequence/failure analysis.

ii. Expected activated life before self-depletion.

iii. Hang-fire analysis.

4. LITHIUM BATTERY-POWERED SYSTEM DESCRIPTION.

a. Description of system’s purpose and function.

b. Manufacturer. Name, address, phone number.

c. Model number and/or part number, and device name.

d. Battery installation. Mounting, seals, electrical connectors, etc…

e. Battery housing/container, strength, and free volume, if applicable at the system level.

f. Battery pack safety features or venting mechanisms, if applicable at the system level.

Provide description of the safety features and estimate of operational venting pressure.

g. Current drain. Load profile of the system.

h. Diagram of the system’s overall mechanical interfaces. Diagram shall show proximity to other equipment and energetic sources.

i. Block diagram of system interfaces to the battery. Electrical and physical interfaces.

j. Electrical schematic. Schematic shall show the fuses, blocking diodes, relays, etc… and external power interfaces.

k. Charger and charge control mechanism. Provide description of the charger and charge control mechanisms if applicable. Discuss if cells are individually equilibrated, or is the battery charged as a series/parallel string. For large form lithium batteries, provide information on charging system safety including design, validation and testing.

l. Other safety controls and mitigations. Provide description of other safety controls or mechanisms such as a Battery Management System (BMS), software shutdown mechanism, etc…

5. CONCEPT OF OPERATIONS (CONOPS) AND LOGISTICS. CONOPS and logistics information shall be provided for both ashore, aloft and afloat use of the lithium battery. For systems going aboard Naval ships and submarines for transportation and/or deployment, logistical information pertaining to stowage location, charge location, sparing plan, and emergency response plan shall be provided. It is acceptable to provide the relevant information from another document source.

a. Packaging. How will the system and battery be packaged?

b. Transportation methods. How will the system and battery arrive at the use location?

c. Storage facilities. How will the system and battery be stored from delivery to disposal?

d. Disposal information. How will the battery be disposed?

e. CONOPS for ashore, aloft and afloat

i. Detailed description of how the system and batteries will be used and handled.

ii. Platform (s) that will transport or deploy the system. Naval facilities, range crafts, Naval aircrafts, and/or Naval ships and submarines. If Naval aircraft and ships/submarines are identified, provide a complete list of aircrafts and platforms by name.

iii. Location of charging operations, if applicable.

iv. Location of stowage for system and batteries, including spares. Aggregate storage of 1,000 Wh or lower per location/locker is imposed on Naval afloat platforms.

v. Launch and Recovery operations, if applicable.

vi. Number of units anticipated to be used, and/or transported, including spares.

vii. The sequence of events before system use, activation, or deployment, if applicable.

viii. Replacement and sparing plan. Describe the battery replacement plan, including number of batteries needed to support system during deployment.

ix. Identify other batteries and battery powered devices it is packed or stored with and their quantities, if applicable.

6. MAINTENANCE PROCEDURES, OPERATING PROCEDURES, CASUALTY PROCEDURES AND/OR

DRAFT TEMPORARY STANDING ORDERS (TSO) FOR US NAVY SHIPS OR SUBMARINES. Provide all battery maintenance procedures to be conducted while underway. Provide any procedure which impacts safe handling or operation of the battery system. Provide any unique casualty procedures or procedures which deviate from standard shipboard firefighting procedures.

a. Charging. Outline procedures for charging including whether manned charging is required.

b. Firefighting. Outline unique firefighting procedures such as immediate use of water over extinguishers, ventilation valve line-ups, or other changes from standard shipboard firefighting procedures.

c. Deluge procedures. Outline how and when deluge should occur, if applicable.

d. Watchstanding. Outline watchstanding or other continuous or periodic monitoring requirements.

e. Maintenance. Outline any battery related maintenance conducted while underway including periodicity.

7. FUNCTIONAL, ENVIRONMENTAL AND SAFETY TEST DATA. Functional, environmental and safety tests representative of the actual environments to be encountered by the complete end item, including the battery, performed to date. This shall include the description of the testing performed, results, and supporting data. Data may include results from battery testing conducted by other services or agencies, manufacturers, or independent evaluators, e.g.

Underwriters Laboratories (UL).

8. SAFETY TESTING PROGRAM PLAN OR COMPLETED TEST DATA. Proposed safety testing program plan or completed test results from the specific lithium battery safety abuse tests identified in chapter 13 of S9310 revision 3.

9. SYSTEM SAFETY PROGRAM (SSP). Summarized results from the System Safety Program should be submitted with the safety data package. Specifically, the preliminary hazard list and hazard analysis data must be supplied. For systems going on US Navy ships and submarines, a draft Hazard Assessment Report (HAR), in accordance with SER 05S/2019-135 dated 15 AUG 2019, is required for all hazards.