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Report on
“Developing Chemistry agnostic standards for
energy storage technologies”





























May, 2024






Acknowledgements
This report has been prepared under the guidance of Dr. V. K. Saraswat, Member (Energy),
NITI Aayog. A technical group was created under Sh. Rajnath Ram, Adviser (Energy), NITI
Aayog, with members Sh. M. A. K. P. Singh, Member (Hydro), CEA, Sh. Kuldeep Rana,
Scientist E, MNRE, Sh. Neeraj Kushwaha, Asst. Director, BIS, Dr. AS Prakash, Sr. Principal
Scientist, CSIR-Central Electro Chemical Research Institute, Karaikudi, Sh. Yogesh Sharma,
Professor, Energy Storage Laboratory (ESL), IIT Roorkee, Dr. Raman Vedarajan, Senior
Scientist, International Advanced Research Centre for Powder Metallurgy & New Materials
(ARCI), Hyderabad, Sh. Abhijit Datta, AGM, Chakr Innovation, Sushri Abhilasha Meena,
Chakr Innovation, Sh. P M Nanda, Greenko, Dr G Ganesh Das Chief - Collaboration &
Innovation, TATA Power, Sh. Bhupesh Verma Manager, India Energy Storage Alliance, Dr.
Deepanjan Majumdar, Office of Member (Energy), NITI Aayog and Sh. Manoj Kumar
Upadhyay, Dy Adviser (Energy), NITI Aayog as Member Secretary for the group.

We acknowledge all other stakeholders who contributed in finalization of the Report on
“Developing Chemistry agnostic standards for energy storage technologies ".





















































Contents
Executive Summary .................................................................................................................... i
1. Background ........................................................................................................................... 1
1.1 India’s Climate Commitments ...................................................................................... 1
2. Energy storage - a critical role for driving India’s energy transition .................................... 3
2.1 Energy Storage Technologies and its and Types .......................................................... 5
2.2 Capacity of Storage Technologies ................................................................................ 6
2.3 Emerging Battery Storage Technologies ...................................................................... 7
3. Key findings of the review of Standards on Testing and Certification for Energy Storage 11
4. Need for Chemistry Agnostic Standards .......................................................................... 17
5. Chemistry Agnostic Parameters ....................................................................................... 19
5.1 Technical Parameters .................................................................................................. 19
5.2 Safety Requirements ................................................................................................... 29
6. Recommendations ................................................................................................................ 46
6.1 Modification of existing standards for application specific testing of emerging
Energy Storage technologies ............................................................................................ 46
6.2 Quality and Standards for Connectivity to the Grid ................................................... 46
6.3 Establishing the Testing Infrastructure for Emerging Energy Storage Technologies
.......................................................................................................................................... 46
6.4 Capacity Building: ...................................................................................................... 47
6.5 The Template for Chemistry Agnostic Standards ...................................................... 47
Annexure-I ............................................................................................................................... 71
Annexure-II .............................................................................................................................. 73
Annexure-III ............................................................................................................................ 75
Annexure-IV ............................................................................................................................ 86
Annexure-V.............................................................................................................................. 90
Annexure VI............................................................................................................................. 93









Tables
Table 1: NITI Aayog & RMI 2022 battery demand outlook (conservative scenario) ............... 3
Table 2: NITI Aayog & RMI 2022 battery demand outlook (accelerated scenario) ................. 4
Table 3: Types of storage technologies ..................................................................................... 5
Table 4: Technology Maturity Level ......................................................................................... 6
Table 5: Capacity of Storage technologies ................................................................................ 7
Table 6: Emerging Storage technologies (Beyond Li-ion) ........................................................ 8
Table 7: IS 6303 - Primary Batteries— General ...................................................................... 12
Table 8: IS 16048-1 – Secondary Cells and Batteries Containing Alkaline or Other Non-acid
Electrolytes — Secondary Sealed Cells and Batteries for Portable Applications Part 1 Nickel-
cadmium. .................................................................................................................................. 13
Table 9: IS 17092– Electrical Energy Storage Systems: Safety Requirements ...................... 14
Table 10: IEC 62933-2- Electrical energy storage (EES) systems – Part 2-1: Unit parameters
and testing methods – General specification ........................................................................... 15
Table 11: IEC 62933-3- Electrical energy storage (EES) systems – Part 3-1: Planning and
performance assessment of electrical energy storage systems – General specification .......... 16
Table 12: Chemistry Agnostic Technical parameters .............................................................. 20
Table 13: Ranges of Chemistry Agnostic Technical parameters ............................................. 24
Table 14: Test condition and acceptance criteria of Safety parameters/ requirements ............ 29
Table 15: Amendment/Adaptive interpretation of AIS156 ..................................................... 31
Table 16: Amendment/Adaptive Interpretation of AIS039 ..................................................... 37
Table 17: Amendment/Adaptive Interpretation AIS038.......................................................... 39


i


Executive Summary

India has made ambitious climate commitments and net-zero emission target by 2070. India is
aiming to reduce Emissions Intensity of its GDP by 45 percent from 2005 level and achieve
about 50 percent cumulative electric power installed capacity from non-fossil fuel-based
energy resources by 2030.
As a part of commitment, the share of Renewable Energy (RE) is likely to increase
significantly, but these renewable sources are inherently variable, weather dependent. The
intermittencies of RE pose challenge to grid stability and reliability of electricity supply.
Energy storage can act as a bridge between renewable energy generation and electricity
demand. During periods of high renewable energy production, excess power can be captured
and stored in the system and the stored energy can then be released back into the grid during
peak demand hours, ensuring a reliable and stable power supply. The energy storages will
become a game-changer in driving India's energy transition.
All the emerging Battery Energy Storage (BES) technologies have different chemistries,
materials, and operating characteristics. This necessitates the requirement of different standards
and protocols to ensure safety, performance, and reliability of these nascent technologies. A
variety of battery energy storage is currently designed for consumer electronics or for vehicle
usage. Likewise, grid storage conditions can be quite different from the conditions for use in
vehicle transportation, which might mean that a different technology could be the preferred
stationary storage technology.
A significant barrier to commercializing innovative battery energy storage technologies lies in
the lack of standards, standardized testing and certification procedures. Most of the existing
standards are limited to specific chemistries and their application. Consequently, neither can
new chemistries be evaluated for battery energy storage, nor can any current application in
Electric mobility or stationary storage be certified with these chemistries using these existing
standards. As the world in general and India in particular has taken initiative for transitioning
to a greener future, several new energy storage technologies are being researched upon,
developed, and rapidly progressing towards commercialization. Making standards for each new
technology for every application is not only time consuming but also requires a certain level of
expertise within the standardising agencies.
To overcome this hurdle and unlock the potential of these niche technologies, India needs to
adopt a chemistry agnostic approach to standards. This framework would evaluate all energy
storage technologies based on universal technical and safety parameters, regardless of their
type.
This shift offers several benefits:
1. Enabling Diverse Technologies: The commercialization of new, potentially more
sustainable energy storage solutions. ii

2. Resource Utilization: Standards can be designed to encourage the use of readily available
materials within India.
3. Innovation and Growth: A flexible framework fosters innovation and attracts investment
in domestic energy storage research, development, and manufacturing ecosystem.
This report puts forward the technical and safety parameters necessary to establish a set of
standards within this framework that are agnostic to chemistry. A sample template for such a
standard is also proposed. Furthermore, it recommends flexible interpretations and adjustments
of current application standards to ease the incorporation of new energy storage technologies
into electric vehicles (EVs) and stationary energy storage systems within the given framework.
From this report, the following key recommendations have emerged:
(a) Formulation of Chemistry Agnostic Standards and notification of guidelines for their use:
India lacks energy storage standards that are agnostic to specific chemistries and technologies.
This poses a challenge for evaluating and integrating the diverse range of emerging
technologies. A range of Technical and Safety Parameters suitable for Chemistry Agnostic
Standards have been identified based on examination of existing standards. A draft template
for developing chemistry agnostic standards for energy storage has been developed in BIS
format. This template can be utilized for development of standards & certifications. It is
recommended that BIS develops and notifies the use of these standards within a period of 3-4
months.
(b) Modification of existing standards for application specific testing of emerging Energy
Storage technologies: India's existing application standards for energy storage technology
(like AIS038, IS039, AIS040, AIS041, AIS048, AIS049, AIS156, AIS039, etc.) inherently
impede certification of emerging energy storage technologies (EST). BIS needs to review and
suitably modify these standards, aligning them with the proposed modifications for facilitating
application specific testing and certification of emerging Energy Storage technologies within a
period of 3-4 months.

Additionally, Indian conditions require operation in ambient temperature in the range of -20 to
60°C. The following safety requirements need to be adhered to:

i. All technologies should ensure safety and accepted performance in these conditions.
ii. In case technologies cannot inherently function safely with acceptable performance in
these conditions, additional thermal management systems need to be mandated.

(c) Update Standards for Connectivity to the Grid: CEA Safety Standards and CEA (Technical
Standards for Connectivity to the Grid) Regulations need to be suitably updated to cover ESS
and other technologies like electrolysers for Green Hydrogen. The Technical Standards may
also cover the ‘Performance Standards’ for different services as well as ‘Operation and
Maintenance Standards’ for ESS facilities.
iii

(d) Establishing the Test Beds for Emerging Energy Storage Technologies: India's energy
storage sector, vital for clean energy integration, suffers from a lack of centralized testing
infrastructure data base. This fragmentated approach leads to unreliable data, hinders
innovation due to inconsistent testing protocols, and limits collaboration due to a lack of
transparent data sharing. The existing central testing and certification agencies, such as
International Centre for Automotive Technology (ICAT) and Automotive Research
Association of India (ARAI) under the Ministry of Heavy Industries (MHI), lack the
necessary equipment and facilities to handle the full range of technical parameters associated
with evolving energy storage technologies. This translates to inaccurate and incomplete testing,
hindering the development and commercialization of reliable storage solutions.

Upgrading the existing testing facilities and establishing new ones require significant
resources. By leveraging government resources and private sector expertise, PPPs model can
be explored to establish high-end testing infrastructure. This collaborative approach will
ensure efficient resource allocation and faster development of the testing infrastructure.

It is also recommended that BIS needs to develop dashboards for centralized testing
infrastructure and include infrastructure, equipment’s, type of test, timelines, testing process,
fee, trained manpower, online application, testing tracking, result and certification to facilitate
the energy storage manufacturers, startups, innovators etc.

(e) Capacity Building: Developing a skilled workforce through targeted training programs for
personnel by BIS in co-ordination with the different user ministries (MHI, Power, MNRE,
Transport etc.). This may ensure expertise in handling the intricacies of diverse energy storage
technologies. By investing in capacity building via these partnerships, India can create a robust
ecosystem that fosters innovation and development in the crucial energy storage sector. This,
in turn, will unlock the true potential of clean energy integration, paving the way for a
sustainable energy future.

By embracing chemistry agnostic standards, India can overcome the limitations of current
technologies and accelerate its clean energy transition. This will enable the development of a
robust and sustainable domestic energy storage industry, ultimately contributing to achieving
its NDC targets and building a cleaner energy future.






1

CHAPTER 1
1. Background
1.1 India’s Climate Commitments
India’s historical cumulative emissions from 1850 to 2019 amount to less than 4 percent of
cumulative carbon dioxide emissions of the world from the pre-industrial era, despite being
home to 17 per cent of the world’s population. Even today India’s annual per capita emissions
remain less than half of the global average (IEA- CO2 Emission in 2023 report).
At the 26
th
session of the Conference of the Parties (COP26) to the United Nations
Framework Convention on Climate Change (UNFCCC) held in Glasgow, United Kingdom,
India expressed to intensify its climate action by presenting to the world five nectar elements
(Panchamrit) of India’s climate action. The updated Nationally determined contributions
(NDCs) translate the ‘Panchamrit’ commitment announced at COP 26 into enhanced climate
targets. The update is also a step towards achieving India’s long-term goal of reaching net-
zero by 2070.
As per the updated NDC, India now stands committed to reduce Emissions Intensity of its
GDP by 45 percent by 2030, from 2005 level and achieve about 50 percent cumulative
electric power installed capacity from non-fossil fuel-based energy resources by 2030. This
also takes forward the Hon’ble Prime Minister’s vision of sustainable lifestyles and climate
justice to protect the poor and vulnerable from adverse impacts of climate change. The updated
NDC reads "To put forward and further propagate a healthy and sustainable way of living based
on traditions and values of conservation and moderation, including through a mass movement
for ‘LIFE’– ‘Lifestyle for Environment’ as a key to combating climate change". The decision
on enhanced NDCs demonstrates India’s commitment at the highest level for decoupling of
economic growth from greenhouse gas emissions.
There are many possible pathways that can be taken up to achieve NZ 2070 emissions at a
national level; however, there exist some barriers and uncertainties that may affect them. For
India, a lot will depend on the pace of innovation in emerging technologies, the extent to which
citizens are able or willing to change their behaviour, the availability of sustainable alternatives
in addition to the extent and effectiveness of technology transfers and support, financial
investments, and capacity building through international cooperation.
The role of Renewable Energy (RE) in Energy Transition and Net Zero:
i. The share of renewable energy (excluding hydro) in installed capacity as on 31
st
March,
2024 was 143.64 GW. This is expected to increase to 500 GW by 2030 and more than
1200 GW by 2047. Furthermore, as we move towards net zero, the share of renewable
energy will continue to increase.
ii. In the given landscape, the role of energy storage particularly battery energy storage
and other types of storage are also expected to multiply.

2

Therefore, it is important to develop Chemistry Agnostic Standards for different types of
storages for increased penetration of RE. In the next chapter, the critical role of energy
storage in driving energy transition has been detailed.


























3

CHAPTER 2
2. Energy storage - a critical role for driving India’s energy transition
Renewable sources are inherently variable, generating power based on weather conditions. This
intermittency poses a significant challenge to grid stability and reliable electricity supply. The
core challenge with renewable energy is its inability to consistently match electricity demand.
Solar panels produce no power at night, and wind turbines are dependent on wind speeds. This
variability can lead to grid instability and power outages if not addressed. Energy storage
systems act as a bridge between renewable energy generation and electricity demand. During
periods of high renewable energy production, excess power can be captured and stored in these
systems. This stored energy can then be released back into the grid during peak demand hours,
ensuring a reliable and stable power supply. Thus, energy storage will emerge as a game-
changer, playing a critical role in driving India's energy transition.
The Central Electricity Authority’s (CEA) Optimal Generation Mix 2029-30" latest optimal
generation mix report indicates that India will need at least 41.7 gigawatt (GW)/208.3
gigawatt-hour (GWh) of Battery Energy Storge System (BESS) and 18.9GW of Pump Hydro
System in the 2029-30. In a different study by NITI Aayog and RMI, the battery storage demand
ranges from 109 GWh/per year to 338 GWh/per year.
Table 1: NITI Aayog & RMI 2022 battery demand outlook (conservative scenario)

202220262030
Passenger EVs137
Commercial EVs025
E 2-wheeler/3-wheeler 0611
E-buses1412
Freight027
Stationary storage (grid scale)0843
Behind the meter (Residential +
Commercial)
023
Consumer electronics 4711
Rail + Defense234
Market size136
1
3
6
0
1
2
3
4
5
6
7
0
20
40
60
80
100
120
Market size ($ billion)
Annual demand (GWh/year)
India Battery Demand Outlook (conservative scenario)

4

Table 2: NITI Aayog & RMI 2022 battery demand outlook (accelerated scenario)

Also, energy storage technology can facilitate greater penetration of renewables into the grid
without compromising power quality or security and hence facilitate a faster transition away
from traditional fossil fuel-based energy reserves.
Additionally, energy storage offers significant economic benefits in the context of India's
energy transition. By storing excess renewable energy and releasing it during peak demand
periods, energy storage reduces dependence on expensive peak power plants, leading to cost
savings for consumers and utilities. Moreover, energy storage systems allow for participation
in electricity markets by enabling optimized power dispatch based on real-time prices. This
facilitates a more dynamic and efficient electricity market, potentially leading to lower overall
power costs.
Beyond just energy storage, energy storage systems offer a multitude of benefits for grid
management:
i. Grid Balancing and Ancillary Services: Energy storage systems can participate in
electricity markets, providing real-time frequency and voltage regulation, crucial for
grid stability.
202220262030
Rail + Defense4810
Consumer Electronics 101830
Behind-the meter (Res + Comm) 058
Stationary Storage (Grid-scale)020120
Freight1520
E-buses21035
E 2-wheeler/3-wheeler 11530
Commercial Evs1515
Passenger Evs2820
Market Size2615
2
6
15
0
2
4
6
8
10
12
14
16
18
0
50
100
150
200
250
300
350
Market Size ($ Billion)
Annual Demand (GWh/Year)
India Battery Demand Outlook (accelerated scenario)

5

ii. Deferring Infrastructure Upgrades: By storing excess renewable energy, energy
storage systems can reduce peak demand, potentially delaying the need for expensive
transmission and distribution infrastructure upgrades.
iii. Cost Optimization: Energy storage can be used strategically to reduce reliance on
expensive peak power plants and minimize congestion costs on the grid.
iv. Firming Up Renewables: Batteries can compensate for the intermittency of
renewables, ensuring reliable power supply.
v. Decarbonization: Integrating renewables with energy storage displaces fossil fuel
generation.
Thus, energy storage is not simply a technological solution, but a key enabler for India's clean
energy transition.
2.1 Energy Storage Technologies and its and Types
Technologies use a diverse nature of energy storage today - pumped hydro, concentrated solar
thermal, capacitors, Lead Acid batteries, Lithium-ion batteries, etc. - which find diverse nature
of application from large scale storage for energy generation purpose to short duration
applications like mobility and devices. According to the form of storage energy, technologies
can be broadly classified as mechanical, electrochemical, thermal and electrical. The following
Table 3 & 4 give a detailed outline of the different types of storage technologies being
envisaged and the corresponding maturity levels, respectively.
Table 3: Types of storage technologies
Mechanical Electrochemical Thermal Electrical Chemical
Pumped Hydro
Storage (PHS)
Lead Acid Batteries,
Advanced Lead Acid
(Lead Carbon,
Bipolar Lead Acid)
Sensible –
Molten Salt,
Chilled Water
Super
Capacitors
Power-to-Power
(Hydrogen Fuel
Cell, etc)
Compressed Air
Energy Storage
Lithium Batteries
(LCO, LMO, LFP,
NMC, LTO, NCA)
Latent – Ice
Storage
Superconductin
g Magnetic
Energy Storage
(SMES)
Power-to-Gas
Flywheel Energy
Storage
Flow Batteries (ZnBr,
Vn Redox)
Thermochemical
Storage

Solid Gravity
Energy Storage
Sodium Ion (NaS,
NaNiCl2)

Phase Change
Materials
Aluminium, Iron and
Zinc Air batteries




6

LCO-Lithium-Cobalt-Oxide, NCA-Nickel-Cobalt-Aluminum, NMC-Nickel-Manganese Cobalt,
LMO – Lithium Manganese Oxide, LFP– Lithium Iron Phosphate, LTO - lithium-titanium-
oxide
Source: Study on Advanced Grid-Scale Energy Storage Technologies by Department of
Hydro and Renewable Energy, IIT Roorkee, October, 2023
Table 4: Technology Maturity Level

Source: Source: Study on Advanced Grid-Scale Energy Storage Technologies by Department of Hydro and
Renewable Energy, IIT Roorkee, October, 2023
2.2 Capacity of Storage Technologies
In Table 5 the storage capacities for different technologies have been illustrated. It is evident
from the illustrations that PHS, is the most ancient, mature technology, and comprises of
majority of the installed storage technology globally. While PHS is not a battery technology
and does not involve the use of specific chemicals, it does provide a way to store energy in the
form of potential energy, using water as the medium. PHS or in other terms water battery
includes the interaction with VRE (Variable Renewable Energy) ensuring power availability
and robustness of clean energy transition strategy. Large scale, long‐term storage, which will
be required for seasonal backup or as energy security reserves in the absence of fossil fuels,
will require a different technology. Hydrogen storage has the potential to fulfil this role and,
therefore, the future grid is likely to be one where hydrogen plays a significant and crucial role,
not in competition but in concert, alongside various other storage technologies. Moreover,
power to hydrogen and power to methane technologies are still at the nascent stages of research
and deployment.
Battery storage technology or Electrochemical storage technology plays a significant role
starting from grid ancillary services, electric vehicles to consumer electronics and acts as one
of the major pillars for electrical energy storage. However, battery storage technology has
limitations in terms of storage capacity and so is not suitable for every application. An
increasing level of policy and regulatory support, combined with the rapid advances in energy

7

storage technology and significant cost declines are creating enabling conditions for a rapid
growth of the electric mobility market. According to RMI’s research and Bloomberg New
Energy Finance’s (BNEF’s) analysis, the global demand for lithium-ion batteries is expected
to reach more than 2.8 TWh annually by 2030, with a vast majority of that demand serving
electric transportation. Similar momentum is emerging in Energy Storage System (ESS)
applications. Investment in stationary energy storage globally reached US$ 6.3 billion in 2020.
It is expected to continue at a rapid pace reaching US$22 billion by 2025 and more than US$30
billion by 2030.
Table 5: Capacity of Storage technologies

Source: Study on Advanced Grid-Scale Energy Storage Technologies by Department of
Hydro and Renewable Energy, IIT Roorkee, October, 2023

2.3 Emerging Battery Storage Technologies
Lithium-ion batteries have been the dominant energy storage technology for many years due
to their high energy density, long cycle life, and other advantages. However, there are
limitations to lithium-ion batteries, such as the risk of thermal runaway, limited availability of
raw materials, and high costs applications. As a result, there is an increasing interest in
exploring alternative energy storage technologies, such as flow batteries, sodium-ion batteries,
aluminium air batteries, zinc-air batteries, and hydrogen fuel cells, among others. Flow
batteries are popular for both utility scale and residential applications, such as vanadium (e.g.
Ultra Energy) and zinc bromine systems (e.g. Redflow). Other emerging technologies include
iron flow batteries, zinc air batteries, aluminium air batteries; and power system technologies
like vehicle to grid (V2G) and vehicle to everything (V2X) applications. The following Table
6 exhibit a vivid idea on the emerging battery storage technologies.

8


Table 6: Emerging Storage technologies (Beyond Li-ion)
Cell
Schema
tics
Advantages Drawbacks Applications Major Developments
Flow
Battery
• Offers very
long cycle
life because
anolyte and
catholyte are
stored in
external
tanks
• High power
and voltage
delivery
performance
• Low specific
energy
• Requires
special housing
for thermal
safety
• High system
costs currently
• Long-duration
storage;
typically used
for stationary
applications
such as power
backup
(replacing
diesel
generators,
transmission
and distribution
upgrades, etc.)
• ESS Inc. announced a deal
in fall 2021 to supply 2
GWh of iron flow batteries
to utilities through the US,
and v n begun operations
to sell iron flow batteries
in Europe.

• VFlow Technologies has
announced two trial
projects to use vanadium
redox flow batteries to
support EV charging in
South Korea and Australia
Sodium
Sulphur
• Very high
cycle life
• Good
specific
energy
• Low input
material
costs;
cost
competitive
with
traditional
LiBs
• Uses
environmenta
lly benign
materials
• High
temperatures
required for
operation raise
safety concerns
and require
special housing
• Currently high
system costs
Long-duration
storage; grid
support
applications
• NGK Insulators already
supplies commercial
sodium-sulphur batteries
for grid-scale storage;
commissioned a long-
duration storage test project
in 2021 with BASF in
Belgium

• Material research for
advanced electrolytes that
inhibit dendrite growth is
ongoing at University of
Texas in Austin
Sodium
Ion
• Low
material cost
for sodium,
more
abundant and
• Currently in
initial
commercialisati
on phase,
• Grid-scale
storage
• Reliance New Energy
Solar announced
acquisition of Faradion
Ltd., a UK-based battery
maker specialising in
sodium-ion technology; it
plans to use the technology

9

sustainably
sourced
• Allows easy
and safe
transport
without loss
of
performance
• Low
tendency for
dendrite
growth on
charging
has not achieved
scale
• Relatively
lower energy
density and
cycle life
performance
for a domestic
manufacturing plant in
Gujarat

• CATL announced first-
gen sodium-ion battery in
2021 which can offer up to
160 Wh/kg energy density
and fast charging; aims at
target 200 Wh/kg
Zinc Air
• High
theoretical
energy
density
• Higher
safety
performance
compared
with
incumbent
LiBs
• Low-cost
materials for
the electrodes
allow lower
overall
manufacturin
g cost
• Technology
has not reached
mass market
penetration;
currently
expensive to
manufacture
rechargeable
zinc-air batteries
• India has
limited zinc
reserves
• Small
consumer
electronics
• Potential use
in long duration
storage
• Technology still in R&D
phase (advanced materials
research)
Alumini
um Air
• High
theoretical
energy
density,
lightweight
• Easily
recyclable
cell raw
• Technology
still in early
R&D stage
• Typically
nonrechargeable
,
so battery
replacement
• Long-range
EVs and
unmanned air
vehicles
(UAVs)
• Technology still in R&D
phase (advanced materials
research)

10

material
• Not
susceptible to
thermal
runaway
• India has
abundant
aluminium
reserves
stations need to
be built out
if the technology
achieves
commercialisati
on
Superca
pacitors
• Very high
cycle life
• Good
specific
energy
• Low input
material
costs;
cost
competitive
with
traditional
LiBs
• Uses
environmenta
lly benign
materials
• High
temperatures
required
for operation
raise safety
concerns and
require special
housing
• Currently high
system costs
• Fast-response
grid support
applications
• Medical
devices and
consumer
electronics
• Researchers at companies
are developing different
materials, such as various
carbon materials, mixed-
metal oxides, and
conducting polymers for
supercapacitor electrodes.
Advances in carbon-based
materials, namely
graphene, can increase the
energy density to nearly
the level of batteries
Source: Study by NITI Aayog and RMI, 2020
Given the significant role and scale of energy storage, availability of critical material used in
energy storage technology will become a major challenge in the long run. Hence, new and
diverse energy storage technologies need to be adopted. With their distinctive advantages, these
diverse technologies will become economically, technologically and environmentally more
suited in some applications than others. Standards which would facilitate testing and
certification, are hence required to not only keep up with the pace of innovation but also to
facilitate commercialization and deployment of these new and emerging energy storage
technologies. In this regard, the commonly available standards relating to Energy storage that
intend to cover multiple technologies and chemistries, have been reviewed in the next chapter


11

CHAPTER 3
3. Key findings of the review of Standards on Testing and Certification
for Energy Storage
The commonly available standards relating to Energy storage that intend to cover multiple
technologies and chemistries, have been reviewed for their technical scope and safety
requirements.
The key findings are as follows:
i. Most of the standards are specific to a particular chemistry and a particular application.
India is transitioning to a greener future, several new energy storage technologies are
emerging and progressing towards commercialization. Making standards for each new
technology for every application is not only time consuming but also requires a certain
level of expertise within the standard making agencies. An inaccurate evaluation
procedure or a delayed release of new standards will not only bias the market
acceptance towards a particular technology but also halt research and development in
the emerging technologies.
ii. Some of the standards are not limited by the application. They cover many chemistries
(e.g. IS6303 for Primary Batteries), but the parametric testing conditions are neither
generic nor extendable to include new chemistry or technologies. Not all the emerging
technologies or chemistries can be accommodated within these standards with
appropriate amendments. Also, some of the standards that are used for certification of
products and applications running on energy storage like Electric mobility (e.g.
AIS156, AIS038, AIS039, etc.), do not specifically mention a particular technology
or chemistry like Secondary Lithium ion, but the testing procedure and evaluation
criteria are well defined.
iii. Almost in all the standards on energy storage systems (e.g. IS17092, IEC62933-1,
IEC62933-2, IEC62933-3, etc.), an Energy Storage System has been defined to be an
electrically rechargeable system. This very definition excludes chemistries and
technologies which can be charged and recharged non-electrically (e.g. pumped hydro,
fuel cells, mechanically rechargeable primary batteries, etc.).
iv. In terms of safety and performance, most of the environmental testing procedures and
conditions have been adopted from global standards suited for applications of energy
storage systems in non-Indian conditions. India, being a geographically diverse
country and facing climatic variations hence, technologies certified by these standards
might not be suitable in terms of safety and performance in actual Indian conditions.
There is also non-uniformity in these test conditions among the existing standards.
Some of the clauses and sections which limit the scope of the reviewed standards to cover a
wider range of chemistries and technologies are noted below:



12

Table 7: IS 6303 - Primary Batteries— General
Clause/
Section
Details Limitations
Scope This standard specifies requirements
to standardize primary batteries with
respect to their electrochemical
system, dimensions, nomenclature,
terminal configurations, markings,
test methods, typical performance,
safety, and environmental aspects.
The objective of this standard is to
benefit primary battery users, device
designers and battery manufacturers
by ensuring that batteries from
different manufacturers are
interchangeable according to
standard form, fit and function.
Furthermore, to ensure compliance
with the above, this part specifies
standard test methods for testing
primary cells and batteries.
This standard is limited to only
dry cell or batteries.
It does not include primary flow
batteries like metal air flow
batteries or hydrogen fuel cells
Clause
3.3
Definition - Dry (Primary) Battery
Clause
3.5
Definition - End-point Voltage (EV) Discharge can be terminated if
any of following condition is
reached depending upon type of
energy storage technology:
a) End Point Voltage
b) End Point Current
c) End Point Power
Clause
4.1.4 -
Table 3
Standardized Electrochemical
systems
It does not include primary flow
batteries like metal air flow
batteries or hydrogen fuel cells
Clause
6.7
Activation time Generic formula or procedure of
finding activation time which is
extendable to other primary
batteries is not provided

13

Clause
6.1
Table 4
Conditions for Storage before and
during discharge Testing
Discharge conditions do not
include high temperature or low
temperature testing as required
by Indian conditions

Table 8: IS 16048-1 – Secondary Cells and Batteries Containing Alkaline or Other Non-acid
Electrolytes — Secondary Sealed Cells and Batteries for Portable Applications Part 1 Nickel-
cadmium.
Clause/Section Details Limitations
Title Secondary cells It does not include primary
batteries or hydrogen fuel
cells
Title Sealed cells It does not include flow
batteries
Scope Specific to Ni-Cd and small
power applications like portable
It is specific to Ni-Cd Systems
Clause 7.1 Charging procedure for test
purposes
This procedure is not
applicable for primary battery
batteries as it cannot be
electrically charged
Clause 7.3.3 Discharge performance at –18 °C Some batteries may not
perform at this temperature
Clause 7.3.4 Discharge performance for rapid
charge cells (R cells)
It is not applicable for primary
battery batteries as it cannot
be electrically charged
Clause 7.5 Endurance This procedure is not
applicable for primary battery
batteries as it cannot be
electrically charged
Clause 7.6 Charge acceptance at constant
voltage

Clause 7.7 Overcharge It is not applicable for non-
electrically recharging
batteries



14

Table 9: IS 17092– Electrical Energy Storage Systems: Safety Requirements
Clause/Section Details Limitations
Clause 3.2 Definition - Energy Storage (ES)
System — Equipment that
receives electrical energy and
then provides a means to store
that energy in some form for later
use in order to supply electrical
energy when needed. EES are
classified into mechanical,
electrochemical, chemical,
electrical and thermal energy
storage systems, as shown in Fig.
1.
Although this clause, covers most
of the chemistries that can be
classified into electrically
rechargeable type, but it is not
applicable for primary batteries. It
does not cover all types of the
energy storage systems.

Clause 3.2 (a) Electrochemical energy storage
system — Consists of a
secondary (rechargeable) battery
electrochemical capacitor, flow
battery or hybrid battery-
capacitor system that stores
electrical energy and any
associated controls or devices
that can provide the stored
electric energy upon demand.
Although this clause, covers most
of the chemistries that can be
classified into electrically
rechargeable type, but it is not
applicable for primary batteries.
It does not cover all the
electrochemical energy storage
system
Clause 3.2
Examples
Electrochemical Input Energy -
Charger
This example is limited to
secondary systems and does not
cover electrically not rechargeable
systems.
Clause 3.16 Ambient Temperature – 35 ± 5
degrees
Inconsistency in the values when
compared with other standards
Clause 24.2 Ambient Temperature – 35 ± 5
degrees
Inconsistency in the values when
compared with other standards

IEC 62933-1 - Electrical energy storage (EES) systems – Part 1: Vocabulary: The
limitations in this part of standard are the same as that of IS17092.



15

Table 10: IEC 62933-2- Electrical energy storage (EES) systems – Part 2-1: Unit parameters
and testing methods – General specification
Clause/Section Details Limitations
Clause 6.2.2.2 Input active power test This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause 6.2.3 Roundtrip efficiency test This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause 6.2.4 Expected service life test This clause is limited to secondary
systems and does not cover
electrically not rechargeable systems.
Clause 6.2.5 System response test,
step response time and
ramp rate
This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause 6.2.6 Auxiliary power
consumption test
This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause 6.2.7 Self-discharge of EES
system test
This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause 6.4.6.3 Operating cycle test
(input and output power
operating test)
This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause 6.4.8 Available energy test This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Annex C Back-to-back test method
for EES system
This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.





16

Table 11: IEC 62933-3- Electrical energy storage (EES) systems – Part 3-1: Planning and
performance assessment of electrical energy storage systems – General specification
Clause/Section Details Limitations
Clause 5 Planning of EES Systems
– rated input and output
power
This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause5.4,
Table1
Main electrical
parameters of EES
systems
This clause is limited to secondary
systems and does not cover non-
electrically rechargeable systems.
Clause 5.4.9 End-of-service life
values
This clause is limited to secondary
systems and does not cover
electrically not rechargeable systems.






















17

CHAPTER 4
4. Need for Chemistry Agnostic Standards
All the emerging Battery Energy storage technologies have different chemistries, materials,
and operating characteristics. As reviewed in the previous chapter, the available standards that
cover electrical energy storage and multiple battery chemistries are also limited by their very
scope and cannot be applied to the new emerging technologies. This necessitates the
requirement of different standards and protocols to ensure the corresponding safety,
performance, and reliability of the emerging technology. Against this backdrop, experts, and
technical teams, experience a variety of problems regarding application of such technologies:
i. Different technologies respond to a particular use case (applications) differently, and
so testing is needed for many of the use cases and often in the country where the storage
will be deployed at scale.
ii. The use cases for energy storage are complex, particularly for the broad range of electric
system configurations in developing economies.
iii. Potential lack of quality across battery technology providers is sometimes difficult to
determine initially.
iv. Because of the above issues, the users, like discoms, EV manufacturers, solar power
producers etc. are unable to incorporate different chemistry technologies for energy
storage in their system. Further, they are also uncertain about acquiring the storage
capacity and treating them as an asset for investment.
v. A variety of battery storage is currently designed for consumer electronics or for vehicle
usage. Like the issue above, grid storage conditions can be quite different from the
conditions for use in vehicle transportation, which might mean that a different
technology could be the preferred stationary storage technology.
vi. With the advancement in R&D, new storage technologies are announced within short
time spans as a breakthrough with both significant funding and an appealing potential.
These emerging technologies (gravity, liquid air, geothermal, thermal) do not have
testing standards or commissioning protocols.
To address these limitations and gaps, a chemistry agnostic framework of standards for energy
storage would be vital. An assorted set of these common standards and protocols should be
designed, preferably demonstrating the suitability of the storage-type for the target application.
This format hereby appeals for a chemistry agnostic approach and applicable for most of the
emerging chemistries or technologies that are progressing towards commercialization within
the next 5-10 years. Other standards may include testing protocols, durability requirements,
and regulatory compliance measures. Moreover, the protocols should contain the essence to
attract technology transformation and future R&D prospects, enabling the most appropriate
technological utilization.

18

In the subsequent section, the technical parameters and safety requirements for technologies
for various energy storage have been examined and suitable parameters common for different
storage technologies have been recommended.























19

CHAPTER 5
5. Chemistry Agnostic Parameters
The various Chemistry Agnostic Parameters detailed in this chapter are based on analysis of
existing standards and literature survey of research publications and certification standards.
Any Energy storage technology can fundamentally be defined by the following operational
parameters:
5.1 Technical Parameters
A total of 23 parameters have been identified which need to be defined in terms of their
operability in energy storage technology. These parameters are independent of chemistry or
technology and hence agnostic in nature. For simplicity of understanding, these technical
parameters and specifications can be grouped as follows, to include in chemistry agnostic
standard:
i. Electrical
Electrical specifications include definitions on voltage, power, state of charge, capacity,
and standard parameters of operation for charging and discharging, etc.
ii. Time
This includes parameters that specify time during operation like average duration for
charging and discharging.
iii. Performance
This includes parameters on performance and operational energy losses like round trip
efficiency, etc.
iv. Size and Weight
This includes parameters like energy density that indirectly indicate the size and weight
of the system.
v. Life
This includes parameters that specify life like cycle life, service life, calendar life, etc.
vi. Environmental
This includes the specifications of ambient environmental conditions of temperature
and humidity during storage and operation.

All 23 parameters have been defined with their standard units of measurement. The following
table displays the range of each technical parameter, their type, and units of measurement for
different chemistries and technologies:


20

Table 12: Chemistry Agnostic Technical parameters
Sr. No. Type Parameters Unit
1. Electrical Operating Voltage Volt (V)
2. Electrical Nominal Voltage Volt (V)
3. Electrical Peak Power –
Electrical Charging
[1]
Watt (W)
4. Electrical Peak Power –
Electrical Discharging
Watt (W)
5. Electrical End Point of
Operation- Electrical
Charging [1]
Volt (V) or Ampere (A) or Watt
(W)
6. Electrical End Point of
Operation- Electrical
Discharging
Volt (V) or Ampere (A) or Watt
(W)
7. Electrical State of Charge or
State of Energy
%
8. Time Average Discharge
Duration
Min or h
9. Time Average Charge
Duration
Min or h
10. Electrical Maximum Storage
Capacity
Wh
11. Electrical Maximum Deliverable
Capacity
Wh
12. Size and Weight Energy Density Wh/kg & Wh/L
13. Performance System Round Trip
Efficiency
%

21

14. Performance Cell Round Trip
Efficiency (Ah and
Wh efficiencies)
%
15. Electrical Standard Parameter-
Electrical Charging
(Constant Voltage.
Constant Current),
constant power, CC-
CV [1]
Volt (V) or Ampere (A)
16. Electrical Standard Test
Parameter- Electrical
Discharging or
capacity tests
(Constant Voltage or
Constant Current,
constant power)
Volt (V) or Ampere (A)
17. Life Life during Cycling Nos. of charge/discharge cycle
18. Life Life during
Operation/Service
hours or days or years
19. Life Life during Non-
Operation/Storage
(Calander life)
hours or days or years
20. Environmental Ambient Temperature
– Operation
(Charge or Discharge)
°C
21. Environmental Ambient Temperature
- Storage
°C
22. Environmental Ambient Humidity –
Operation
(Charge or Discharge)
% RH

22

23. Environmental Ambient Humidity -
Storage
% RH
Notes:
[1] Applicable only for Electrically rechargeable Chemistries

Definition of Technical Parameters and their ranges: All parameters except system round
trip efficiency have been defined for a unit cell which is the smallest unit of the
technology/chemistry which generates electrical energy.

Operating Voltage: The range of voltages within which the unit cell is designed to function
properly and safely.
Nominal Voltage: Suitable approximate value of voltage used to identify the voltage of a unit
cell.
Peak Power- Electrical Charge: It refers to the unit cell’s maximum absorbable input power
capacity during short -duration fast- charging situations without compromising safety.
Peak Power- Electrical Discharge: It refers to the unit cell’s maximum deliverable output
power capacity during short-duration high-demand situations without compromising safety.
End Point of Operation- Charge: It refers to the state or condition of the unit cell when it
reaches a certain predefined level of charge when a charging operation needs to be stopped.

End Point of Operation- Discharge: It refers to the state or condition of the unit cell when it
reaches a certain predefined level of discharge when a discharging operation needs to be
stopped.

State of Charge: It is the remaining charge as a percentage of the maximum charge stored
under operating conditions as declared by the manufacturer.
State of Energy: It is the remaining energy as a percentage of the maximum stored energy
under operating conditions as declared by the manufacturer.
Average Discharge Duration: The time from the commencement of discharge until the unit
cell's end point operation is reached.
Average Charge Duration: The time from the commencement of charge until the unit cell's
end point operation is reached.
Maximum Storage Capacity: The maximum amount of energy that a unit cell can store.
Maximum Deliverable Capacity: The maximum amount of energy that a unit cell can deliver
during standard electrical discharge.
Energy Density: The maximum amount of energy that the unit cell can deliver per unit weight.

23

Cell Round Trip Efficiency: It refers to the ratio of the energy output from the unit cell when
it is discharged compared to the energy input required to recharge it. In simpler terms, it
measures how effectively a cell can store and then release energy.

System Round Trip Efficiency: It refers to the ratio of the energy output from the battery
energy storage system (BESS) when it is discharged compared to the energy input required to
recharge it. It includes all the losses in the BESS, including auxiliary systems and power
conversion units.
Standard Discharge Voltage-Constant Voltage (CV) Discharge: It refers to the Voltage
conditions in which a unit cell needs to be discharged to determine and validate its
characteristic technical parameters.
Standard Discharge Current-Constant Current (CC) Discharge: It refers to the Current
conditions in which a unit cell needs to be discharged to determine and validate its
characteristic technical parameters.
Standard Charge Voltage-Constant Voltage (CV) Charge: It refers to the Voltage
conditions in which a unit cell needs to be charged to determine and validate its characteristic
technical parameters.

Standard Charge Current-Constant Current (CC) Discharge: It refers to the Current
conditions in which a unit cell needs to be charged to determine and validate its characteristic
technical parameters.
Life Cycle: It is the number of charge-discharge cycles in standard operation until acceptable
degradation in performance without compromising safety.

Life during Operation/service: It is the time in hours in standard operation until acceptable
degradation in performance without compromising safety.

Life during Non-Operation /Storage: It is the time in years for storage in manufacturer
defined conditions without compromising safety and acceptable degradation in performance in
standard operation post storage.

Ambient Temperature- Charge Operation: It is the manufacturer defined range of ambient
temperature within which the unit cell can be charged without compromising safety.

Ambient Temperature- Discharge Operation: It is the manufacturer defined range of
ambient temperature within which the unit cell can be discharged without compromising safety.

Ambient temperature- Storage: It is the manufacturer defined range of ambient temperature
within which the unit cell can be stored without compromising safety.
Ambient Humidity- Charge Operation: It is the manufacturer defined range of ambient
humidity within which the unit cell can be charged without compromising safety.

24

Ambient Humidity- Discharge Operation: It is the manufacturer defined range of ambient
humidity within which the unit cell can be discharged without compromising safety.
Ambient Humidity- Storage: It is the manufacturer defined range of ambient humidity within
which the unit cell can be stored without compromising safety.

The following table lists all the defined technical parameters with their range of values. Their
reference sources and assumptions made for their theoretical calculations have been noted
wherever applicable.

Table 13: Ranges of Chemistry Agnostic Technical parameters
Sr.
No.
Technical
Parameter
Metal
Ion
Lead
Acid
Redox
Flow
Metal
Air
Flow
Metal
Sulph
ur
Hydrog
en Fuel
1. Operating
Voltage
(in V)
1.5-4.31
[4][5]
1.7-3 [6] 1-2.4
[7]
0.5-
2.5
0.9-
2.6
0.6-0.8
2. Nominal
Voltage
(in V)
2.4-3.7
[4][5][6]
2.2
[5]
1.4-1.6
[7]
1.2-
1.4
1.25-
2.3
0.6-0.8
3 Peak Power -
Electrical
Charge
(in Watt)
0.2-18
(max:
5Ah,
3.6V, 1C
charge)
[12]
1-180
(max:
180Ah,
2V, 0.5C
charge)
[11]
Up to
135
(max:
95Ah,
1.4V,
1C
charge)
[13]
NA
[2]

66-
1390
[14]
NA
[2]
[10]
4. Peak Power-
Electrical
Discharge
(in Watt)
1-90
(max
5Ah,3.6V
5C
discharge)
[12]
2-360
(max
180Ah,
2V 1C
discharg
e)
[11]
Up to
135
(max
95Ah,
1.4V 1C
discharg
e)
2-100
[31]

50-
1100
[14]
7-125
(Power
density:
Upto 2.5
W/cm
2


25

[13] Sze: 5-
50cm
2
)
[10]
5. End Point-
Charge
(in V)
Up to 4.5
[5]
Up to 3
[6]
Up to
1.65
[7]
NA
[3]
Up to
2.3
NA
[3]
6. End Point-
Discharge
Upto 2V
[4][5]
1.75V
[6]
0.8V
[7]
1W
[31]
0.9V 0.6V
7.1. State of Charge
(in %)
0-100 0-100 0-100 0-100 0-100 0-100
7.2 State of Energy
(in %)
0-100 0-100 0-100 0-100 0-100 0-100
8. Average
Discharge
Duration
(in h)
0.1-8
(min:
0.125C
max: 10C)
[18] [19]
5
[15]
4-12
[17]
3-12
[31]
5-50
[16]
9-10
[20]
9. Average Charge
Duration
(in h)
0.1-8
(min:
0.125C
max: 10C)
[18][19]
14-16
[15]
6-24
[17]
0.05-
0.5
[39]
4-5
[16]
0.25-0.5
[39]
10. Maximum
Storage
Capacity
(Wh)
0.1-23
(max:
5Ah,
charge
Voltage:
4.5V)
3-540 100-
400
[31]
120-
260
[31]


26

11. Maximum
Deliverable
Capacity
(Wh)
0.095- 21
(Cell
Round trip
max:
95%)
2.25-405 70-
360
[31]
100-
250
[31]

12. Energy Density
(Wh/kg)
[32]
100-350
[21][22]
40-60 25-35
[31]
80-
4000
[31]
1274-
2600
[31]
100-300
[31]
13. Cell Round Trip
Efficiency (%)
85-95 70-85 60-65 80-95 85-95 50-70
14. System Round
Trip Efficiency
(%) [34]
50-70 50-65 55-60 70-80 65-85 30-60
[35]
15.1. Standard
Discharge
Voltage -
Constant
Voltage
Discharge
NA
[36]
NA
[36]

1.0-
1.4V
0.6-0.7V
15.2. Standard
Discharge
Current -
Constant
Current
Discharge
35 mA-
5A
[37]
1 A- 180
A
[37]
NA
[36]

NA
[36]

16.1. Standard Charge
Voltage -
Constant
Voltage Charge
NA
[36]

NA
[36]

NA
[36]

NA
[36]

16.2. Standard Charge
Current -
Constant
Current Charge
10mA- 2.5
A
0.3 A- 60
A
NA
[36]

NA
[36]


27

17. Operation/
Service Cycle
(in Charge-
Discharge cycle)
300-5000 500 10000
[33]

100-
2000
[33]
50-
5000
[33]


18. Operation/
Service Life (in
hours)
1200-
4000
~2500 40000-
12000
[33]
3000-
10000
[33]
250-
25000
[33]

19. Storage/ non-
operating life (in
years)
5-10 2-5 20-100
[33]
10-15
[33]
5-15
[33]

5-10
20.1 Ambient
Temperature –
Charge
Operation
-20 to
60°C
[31]
-20 to
60°C
10 °C to
40 °C
[26]
10°C
to
60 °C
[38]

-50°C
to
400°
C
[27][2
8]
10 to
60 °C
[38]
20.2 Ambient
Temperature –
Discharge
Operation
-20 °C to
60°C
[31]
-20°C to
60°C
10°C to
40 °C
[26]
10°C
to
60 °C
[31]
-
50 °C
to
400°
C
[27][2
8]
50°C to
200°C
21. Ambient
Temperature –
Storage
-40°C to
50°C
[31]
-40°C to
50°C
-20°C
to
60 °C
[31]

22.1 Ambient
Humidity –
Charge
Operation
65±20
%RH
[31]
50±15%
RH
5-
95%R
H (no
conde
nsatio
n)
50±1
5
%RH
40-
100%R
H
[30]

28

22.2 Ambient
Humidity –
Discharge
Operation
65±20
%RH
[31]

50±15%
RH
5-95
%RH
(no
conde
nsatio
n)
50±1
5
%RH
40-
100%R
H
[30]
23. Ambient
Humidity –
Storage
65±20
%RH
[31]
50±15%
RH
5-95
%RH
(no
conde
nsatio
n)
50±1
5
%RH

(References are enclosed in Annexure VI)
Notes:

[2] As Metal Air Flow and Hydrogen Fuel Cell cannot be electrically charged, therefore Peak
power during Charge condition is Not Applicable (NA) to both the chemistries.
Peak values have been found from as far as commercially available largest size of unit cells in
each chemistry.
[3] For Metal air flow, end point power is calculated as 0.01 times maximum deliverable output
power.
[31] Claimed in academic/corporate research reports. Not validated by standard laboratories yet
[32] Chemistry dependent values
[33] Claimed in academic/corporate research. Not validated by standard laboratories yet
[34] Losses in the auxiliary systems and power conversion units have been assumed to be
around 20% in a round trip (10% each in charge and discharge)
[35] Losses in the auxiliary systems and power conversion units have been assumed to be
around 10% as there are no losses in mechanical recharging.
[36] Based upon the characteristic discharging/charging nature of the chemistries either a
constant voltage or constant current mode is applicable. The other mode is hence marked as
Not Applicable (NA) in the matrix.
[37] In constant current Charge and discharge, values have been found for commercially
available cells with 1C and C/3 rates respectively (AIS-156)
[38] Represents conditions for non-electrical or mechanical charging.
[39] As Metal Air Flow and Hydrogen Fuel Cell cannot be electrically charged, therefore
mechanical Charge/refilling duration is considered for both the chemistries.



29

5.2 Safety Requirements
Safety Requirements in energy storage depend upon the end application (e.g. electric mobility
or stationary storage). On deliberation of the purpose, acceptance, and testing conditions by the
sub-group of experts, the consensus was that all chemistries or technologies to be used in these
respective application areas are expected to ensure safety against fire, explosion, hazardous
chemical release, or safety against electrical shock either as a unit cell or in configuration of an
energy storage system (ESS). These requirements during normal operation or abuse are defined
by the following 15 parameters:
i. Vibration
ii. Mechanical Drop/Impact/Crush
iii. Mechanical Shock
iv. Over discharge/forced discharge Protection
v. Over Charge Protection (for only electrically rechargeable cells)
vi. Thermal Shock and Temperature Cycling
vii. Over Temperature Protection
viii. Thermal Propagation/runaway
ix. External Fire Resistance
x. Ingress Protection
xi. Short Circuit Protection
xii. Isolation Resistance
xiii. Withstand Voltage
xiv. Insulation Resistance
xv. Battery Management System
The applicable testing conditions and the acceptance criteria for each of the above parameters
have been detailed in the following table:
Table 14: Test condition and acceptance criteria of Safety parameters/ requirements
Sr.
No.
Test for Acceptance
Criteria
Test Condition-
Mobility
Test Condition-
Stationary
1. Vibration No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per
IEC 60086-5,
UL1973
2. Mechanical
Drop/Impact/
Crush
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per IEC
62619, UL1973,
IEC62660
3. Mechanical Shock No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per IEC
60086-5,
UL1973

30

4. Over
discharge/forced
discharge
Protection
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per IEC
62619,
IEC60086-5,
UL1973
5. Over Charge
Protection
(for only
electrically
rechargeable
cells)
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per IEC
62619, UL1973
6. Thermal Shock
and Temperature
Cycling
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per
IEC 60086-5,
UL1973
7. Over Temperature
Protection
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per UL 1973
8. Thermal
Propagation/runa
way
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per
IEC 62619,
UL1973
9. External Fire
Resistance
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per IEC
62619, UL1973
10. Ingress Protection No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per
IEC 60529
11. Short Circuit
Protection
No fire, No leakage,
No explosion
As per
AIS 156 (Cat. L),
AIS038 (Cat. M&N)
As per
IEC 62619,
UL1973
12. Isolation
Resistance
No fire, No leakage,
No explosion
As per AIS 156 (Cat.
L), AIS038 (Cat.
M&N)
As per
IEC 60950
13. Withstand
Voltage
No fire, No leakage,
No explosion
As per AIS 156 (Cat.
L), AIS038 (Cat.
M&N)
As per
IEC 60950

31

14. Insulation
Resistance
No fire, No leakage,
No explosion
As per AIS 156 (Cat.
L), AIS038 (Cat.
M&N)
As per
IEC 60950
15. Battery
Management
System
Existence of
Microprocessor/
controller based
intelligent
management
As per AIS 156 (Cat.
L), AIS038 (Cat.
M&N)
As per
IEC 62619
Notes:

Category L includes 2 Wheelers and 3 Wheelers,
Categories M&N include 4 Wheelers (passenger, commercial, trucks, etc. but excludes trailers)

All the applicable test conditions in the above table refer to respective application standards
like AIS 156, AIS038, AIS039 for their requirements of safety. However, the conditions and
testing procedures mentioned in these standards are implicitly chemistry specific.
Hence, in the following tables, the respective sections in these standards which need to be
amended are listed. These amendments need to be made to ensure that the safety requirements
and their corresponding tests in these application standards also become chemistry agnostic
and can be used for the certification of emerging battery chemistries when used in these
applications. A chemistry agnostic standard as attached in the draft template would comprise
of the technical parameters and safety requirements generic enough to evaluate the technology
independently of its application. The application specific standards with the amendment
mentioned would ensure chemistry agnostic evaluation of the technology in the application
with its specific requirements.

Required Amendment or Adaptive interpretation of application specific standards for
technology development, validation, and Certification

(a) Standard No. AIS 156
Scope of Standard:
SPECIFIC REQUIREMENTS FOR L CATEGORY ELECTRIC POWER TRAIN VEHICLES

Table 15: Amendment/Adaptive interpretation of AIS156
Clause Existing Clause Amendment/Adaptive Interpretation
2.6
"Conductive connection" means the
connection using connectors to an
external power supply when the
REESS is charged.
"Conductive connection" means the connection
using connectors to an external power supply
when the REESS is electrically charged.

32

2.7
"Coupling system for charging the
REESS" means the electrical circuit
used for charging the REESS from an
external electric power supply
including the vehicle inlet or a
permanently affixed charging cable.
"Coupling system for electrically charging the
REESS" means the electrical circuit used for
electrically charging the REESS from an
external electric power supply including the
vehicle inlet or a permanently affixed charging
cable.
2.14
"Electric power train" means the
electrical circuit which includes the
traction motor(s), and may include the
REESS, the electric energy conversion
system, the electronic converters, the
associated wiring harness and
connectors, and the coupling system
for charging the REESS.
"Electric power train" means the electrical
circuit which includes the traction motor(s), and
may include the REESS, the electric energy
conversion system, the electronic converters, the
associated wiring harness and connectors, and
the coupling system if applicable for electrically
charging the REESS.
2.23
"High voltage bus" means the electrical
circuit, including the coupling system
for charging the REESS that operates
on high voltage.
"High voltage bus" means the electrical circuit,
including the coupling system if applicable for
electrically charging the REESS that operates on
high voltage.
2.34
"Removable REESS" means a REESS
that by design can be taken out from
the vehicle by the vehicle user for off-
board charging.
"Removable REESS" means a REESS that by
design can be taken out from the vehicle by the
vehicle user for off-board charging which can be
done both electrically or mechanically.
2.36
"Service disconnect" means the device
for deactivation of the electrical circuit
when conducting checks and services
of the REESS, fuel cell stack, etc.
"Service disconnect" means the device for
deactivation of the electrical circuit when
conducting checks and services of the REESS,
fuel cell stack, flow cell stack, etc.
2.46 None
"Metal air flow cell" means a cell characterized
by the spatial separation of the electrodes and the
movement of the energy storage fluids.
2.47 None
"State of energy" is the remaining energy as a
percentage of the maximum available energy
under operating conditions as declared by the
manufacturer.
2.48
Energy Capacity (Wh)
The total amount of electrical energy that can be
stored in a unit metal air flow cell
5.1.3.3(b)
On-board isolation resistance
monitoring system together with a
warning to the driver if the isolation
resistance drops below the minimum
required value. The isolation resistance
between the high voltage bus of the
coupling system for charging the
REESS and the electrical chassis need
not be monitored, because the coupling
system for charging is only energized
during charging of the REESS. The
function of the on-board isolation
On-board isolation resistance monitoring system
together with a warning to the driver if the
isolation resistance drops below the minimum
required value. The isolation resistance between
the high voltage bus of the coupling system for
electrically charging the REESS and the
electrical chassis need not be monitored, because
the coupling system for charging is only
energized during charging of the REESS. The
function of the on-board isolation resistance
monitoring system shall be confirmed as
described in Annex 6.

33

resistance monitoring system shall be
confirmed as described in Annex 6.
5.1.3.4
Isolation resistance requirement for the
coupling system used to charge the
REESS
Isolation resistance requirement for the coupling
system used to charge the REESS electrically

For the coupling system (used to
charge the REESS and intended to be
conductively connected to the
grounded external AC power supply)
the isolation resistance shall be at least
1 MΩ when the charger coupler is
disconnected. During the
measurement, the REESS may be
disconnected.
For the coupling system (used to electrically
charge the REESS and intended to be
conductively connected to the grounded external
AC power supply) the isolation resistance shall
be at least 1 MΩ when the charger coupler is
disconnected. During the measurement, the
REESS may be disconnected.
5.4.1

Determination of hydrogen emissions during
electrical charging
5.4.2

Determination of hydrogen emissions during
discharging
5.4.2.1

During a normal discharge procedure in the
conditions given in Annex 7, hydrogen emissions
shall be below 125 g during 5 h, or below 25 x t2
g during t2 (in h)
6.7 Overcharge Protection
Overcharge Protection (Applicable only for
electrically chargeable REESS)
Annex 7
DETERMINATION OF HYDROGEN
EMISSIONS DURING THE
CHARGE PROCEDURES OF THE
REESS (See 5.4.2.)
DETERMINATION OF HYDROGEN
EMISSIONS DURING THE ELECTRICAL
CHARGE PROCEDURES OF THE REESS
(See 5.4.1.2.)
Annex 7 -
Fig 7.1
Determination of hydrogen emissions
during the charge procedures of the
REESS
Determination of hydrogen emissions during the
electrical charge procedures of the REESS

34

Fig 7.2


Annex 7 -
Part 5
The test consists in the five following
steps:
The test for hydrogen emission while charging
consists in the five following steps:
Annex 7 -
5.1.1. Initial charge of the REESS Initial electrical charge of the REESS

The test for hydrogen emission while
discharging consists in the five following steps:
(a) Vehicle / REESS preparation;
(b) Discharge of the REESS;
(c) Determination of hydrogen emissions during
a normal discharge
If the vehicle / REESS has to be moved between
two steps, it shall be pushed to the following test
area.
Vehicle Based test
Vehicle preparation
The ageing of REESS shall be checked, proving
that the vehicle has performed at least 300 km
during seven days before the test. During this
period, the vehicle shall be equipped with the
traction battery submitted to the hydrogen
emission test. If this cannot be demonstrated,
then the following procedure will be applied.
Initial mechanical charge of the REESS
The mechanical charge is carried out:
(a) As per manufacturer guideline
(b) In an ambient temperature between 293 K
and 303 K.
Discharges of the REESS

35

The procedure starts with the discharge of the
REESS of the vehicle while driving on the test
track at a steady speed of 70 per cent ± 5 per cent
of the maximum speed of the vehicle during 30
minutes. Pre-discharge activation and Post-
discharge deactivation, if required, shall be
performed as per manufacturer guidelines.
Discharging is stopped:
(a) When the vehicle is not able to run at 65 per
cent of the maximum thirty minutes speed, or
(b) When an indication to stop the vehicle is
given to the driver by the standard on-board
instrumentation, or
(c) After having covered the distance of 100 km.
After discharging is stopped, process of
determining hydrogen emissions should be
started.
Component Based Test
REESS preparation
The ageing of REESS shall be checked, to
confirm that the REESS has performed at least 5
standard cycles (as specified in Annex 8,
Appendix 1).
Initial mechanical charge of the REESS
The mechanical charge is carried out:
(a) As per manufacturer guideline
(b) In an ambient temperature between 293 K
and 303 K.
Discharge of the REESS
The REESS is discharged at 70 per cent ±5 per
cent of the nominal power of the system.
Stopping the discharge occurs when minimum
SOC as specified by the manufacturer is
reached.
After discharging is stopped, process of
determining hydrogen emissions should be
started.

36

Annex 8 -
Appendix
1




Annex 8G OVERCHARGE PROTECTION
OVERCHARGE PROTECTION (Applicable
only for electrically chargeable REESS)
Annex 8G
- 3.2

Discharging
At the beginning of the test, all relevant main
contactors shall be closed.
A constant current discharge shall be performed
if applicable with at least 1/3 C rate but shall not
exceed the maximum current within the normal
operating range as specified by the
manufacturer.
A constant voltage discharge shall be performed
if applicable with at least standard discharge
voltage rate but shall not exceed the maximum
voltage within the normal operating range as
specified by the manufacturer.
The discharging shall be continued until the
tested-device (automatically) interrupts or limits
the discharging. Where an automatic interrupt
function fails
to operate, or if there is no such function then the
discharging shall be continued until the tested-
device is discharged to 25 per cent of its nominal
voltage level or end point power is reached as
described by the manufacturer.
AIS156 SOC SOC or SOE







37

(b) Standard No. AIS 039
Scope of Standard:
Battery Operated Vehicles - Measurement of Electrical Energy Consumption

Table 16: Amendment/Adaptive Interpretation of AIS039
Clause Existing Clause Amendment/Adaptive Interpretation
3.3 The first charging of the battery shall be
carried out as per para 3.5 below, if not
already done.
The first charging (electrical or mechanical) of
the battery shall be carried out as per para 3.5
below, if not already done.
3.5 Initial charge of the battery
Charging the battery consists of the
following procedures. NOTE: “Initial
charge of the battery” applies to the first
charge of the battery, at the reception of
the vehicle. In case of several combined
tests or measurements, carried out
consecutively, the first charge carried
out shall be an “initial charge of the
battery” and the following may be done
in accordance with the “normal charge”
procedure.1
Charging the battery consists of the following
procedures. NOTE: “Initial charge of the
battery” applies to the first charge of the battery
be it electrical or mechanical, at the reception of
the vehicle. In case of several combined tests or
measurements, carried out consecutively, the
first charge carried out shall be an “initial charge
of the battery” and the following may be done in
accordance with the “normal charge”
procedure.1
The initial mechanical charge of the REESS is
carried out:
(a) As per manufacturer guideline
(b) In an ambient temperature between 293 K
and 303 K.
3.5.2.1 Normal charge procedure Normal electrical charge procedure
3.5.2.2 End of charge criteria End of electrical charge criteria
3.5.2.3 None Normal mechanical charge procedure
The initial mechanical charge of the REESS is
carried out:
(a) As per manufacturer guideline
(b) In an ambient temperature between 293 K
and 303 K.
4 Test conditions NA for Metal air flow as standard discharge is
done at CV and not at Constant Current
5.4.3 Charge of the battery Electrical Charge of the battery

38

The vehicle shall be connected to the
mains within 30 minutes after the
conclusion of the Driving Cycle. The
vehicle shall be charged according to
normal charge procedure (Refer clause
3.5.1.2 above). The energy
measurement equipment, placed
between the mains socket and the
vehicle charger, measures the charge
energy E delivered from the mains as
well as its duration. Charging is stopped
after 24 h from the previous end of
charging time to. NOTE In case of any
power disruptions during charging, the
24 h period shall be exceeded according
to the disruption duration. The
maximum total Power disruption of 30
minutes duration is allowed irrespective
of the number of failures. Validity of
the charge shall be discussed between
the technical services of the approval
laboratory and the vehicle’s
manufacturer.
The vehicle shall be connected to the mains
within 30 minutes after the conclusion of the
Driving Cycle. The vehicle shall be charged
according to normal charge procedure (Refer
clause 3.5.1.2 above). The energy measurement
equipment, placed between the mains socket and
the vehicle charger, measures the charge energy
E delivered from the mains as well as its
duration. Charging is stopped after 24 h from the
previous end of charging time to. NOTE In case
of any power disruptions during charging, the 24
h period shall be exceeded according to the
disruption duration. The maximum total Power
disruption of 30 minutes duration is allowed
irrespective of the number of failures. Validity
of the charge shall be discussed between the
technical services of the approval laboratory and
the vehicle’s manufacturer.
The Energy E for mechanically chargeable
metal air flow battery or cell will be calculated
according to electrical energy capacity
multiplied by weight of anode consumed. For
more info refer manufacturer guidelines.











39

(c) Standard No. AIS 038
Scope of Standard
Part I: Safety requirements with respect to the electric power train of motor vehicles of
categories M and N, as defined in Rule 2 (u) of CMVR.
Part II: Safety requirements with respect to the Rechargeable Electrical Energy Storage
System (REESS), of motor vehicles of categories M and N, as defined in Rule 2 (u) of
CMVR.
Table 17: Amendment/Adaptive Interpretation AIS038
Clause Existing Clause Amendment/Adaptive Interpretation
2.5 "Cell" means a single encased
electrochemical unit containing one
positive and one negative terminal,
which exhibits a voltage differential
across its two terminals and used as
rechargeable electrical energy storage
device.
"Cell" means a single encased electrochemical
unit containing one positive and one negative
terminal, which exhibits a voltage differential
across its two terminals and used as rechargeable
(both mechanical and electrical) electrical
energy storage device.
2.6 "Conductive connection" means the
connection using connectors to an
external power supply when the REESS
is charged.
"Conductive connection" means the
connection using connectors to an external
power supply when the REESS is electrically
charged.
2.8 "Coupling system for charging the
REESS" means the electrical circuit
used for charging the REESS from an
external electric power supply including
the vehicle inlet.
"Coupling system for electrically charging the
REESS" means the electrical circuit used for
electrically charging the REESS from an
external electric power supply including the
vehicle inlet.
2.12 "Electric power train" means the
electrical circuit which includes the
traction motor(s), and may include the
REESS, the electric energy conversion
system, the electronic converters, the
associated wiring harness and
connectors, and the coupling system for
charging the REESS.
"Electric power train" means the electrical
circuit which includes the traction motor(s), and
may include the REESS, the electric energy
conversion system, the electronic converters, the
associated wiring harness and connectors, and
the coupling system if applicable for electrically
charging the REESS.
2.25 "High voltage bus" means the electrical
circuit, including the coupling system
for charging the REESS that operates on
high voltage.
"High voltage bus" means the electrical circuit,
including the coupling system if applicable for
electrically charging the REESS that operates on
high voltage.

40

2.36 "Service disconnect" means the device
for deactivation of the electrical circuit
when conducting checks and services of
the REESS, fuel cell stack, etc.
"Service disconnect" means the device for
deactivation of the electrical circuit when
conducting checks and services of the REESS,
fuel cell stack, flow cell stack, etc.
2.54 "Metal air flow cell" means a cell characterized
by the spatial separation of the electrodes and
the movement of the energy storage fluids.
2.55 "State of energy" is the remaining energy as a
percentage of the maximum available energy
under operating conditions as declared by the
manufacturer.
5.1.3.3
(b)
In fuel cell vehicles, DC high voltage
buses shall have an on-board isolation
resistance monitoring system together
with a warning to the driver if the
isolation resistance drops below the
minimum required value of 100 Ω/V.
The function of the on-board isolation
resistance monitoring system shall be
confirmed as described in Annexure VI.
The isolation resistance between the
high voltage bus of the coupling system
for charging the REESS, which is not
energized in conditions other than that
during the charging of the REESS, and
the electrical chassis need not to be
monitored.
In fuel cell vehicles, DC high voltage buses shall
have an on-board isolation resistance monitoring
system together with a warning to the driver if
the isolation resistance drops below the
minimum required value of 100 Ω/V. The
function of the on-board isolation resistance
monitoring system shall be confirmed as
described in Annexure VI. The isolation
resistance between the high voltage bus of the
coupling system for electrically charging the
REESS, which is not energized in conditions
other than that during the charging of the
REESS, and the electrical chassis need not to be
monitored.
5.1.3.4 Isolation resistance requirement for the
coupling system for charging the
REESS
Isolation resistance requirement for the coupling
system used for charging the REESS electrically
For the vehicle conductive connection
device intended to be conductively
connected to the grounded external AC
power supply and the electrical circuit
that is galvanically connected to the
vehicle conductive connection device
during charging of the REESS, the
isolation resistance between the high
voltage bus and the electrical chassis
shall comply with the requirements of
For the vehicle conductive connection device
intended to be conductively connected to the
grounded external AC power supply and the
electrical circuit that is galvanically connected to
the vehicle conductive connection device during
electrically charging of the REESS, the isolation
resistance between the high voltage bus and the
electrical chassis shall comply with the
requirements of paragraph 5.1.3.1. when the
conductive connection is disconnected and the

41

paragraph 5.1.3.1. when the conductive
connection is disconnected, and the
isolation resistance is measured at the
high voltage live parts (contacts) of the
vehicle conductive connection device.
During the measurement, the REESS
may be disconnected.
isolation resistance is measured at the high
voltage live parts (contacts) of the vehicle
conductive connection device. During the
measurement, the REESS may be disconnected.
5.4.2 Determination of hydrogen emissions during
electrical charging
5.4.3 Determination of hydrogen emissions during
discharging
During a normal discharge procedure in the
conditions given in Annex 7, hydrogen emissions
shall be below 125 g during 5 h, or below 25 x t2
g during t2 (in h)
5.4.3.1
6.7 Overcharge protection Overcharge protection (Applicable only for
electrically chargeable REESS)
Annex
8
DETERMINATION OF HYDROGEN
EMISSIONS DURING THE CHARGE
PROCEDURES OF THE REESS (See
5.4.2.)
DETERMINATION OF HYDROGEN
EMISSIONS DURING THE ELECTRICAL
CHARGE PROCEDURES OF THE REESS
(See 5.4.1.2.)
Determination of hydrogen emissions during the
electrical charge procedures of the REESS
Annex
7 - Fig
8.1
Determination of hydrogen emissions
during the charge procedures of the
REESS

42

Fig 8.2

Annex
8 - Part
5
The test consists in the five following
steps:
The test for hydrogen emission while charging
consists in the five following steps:
Annex8
5.1.1.2.
Initial charge of the REESS Initial electrical charge of the REESS
Annex
8 - 5.3.
The test for hydrogen emission while
discharging consists in the five following steps:
(a) Vehicle / REESS preparation;
(b) Discharge of the REESS;
(c) Determination of hydrogen emissions during
a normal discharge
If the vehicle / REESS has to be moved between
two steps, it shall be pushed to the following test
area.
Vehicle Based test.
Vehicle preparation
The ageing of REESS shall be checked, proving
that the vehicle has performed at least 300 km
during seven days before the test. During this
period, the vehicle shall be equipped with the
traction battery submitted to the hydrogen
emission test. If this cannot be demonstrated,
then the following procedure will be applied.


43

Initial mechanical charge of the REESS
The mechanical charge is carried out:
(a) As per manufacturer guideline
(b) In an ambient temperature between 293 K
and 303 K.
Discharges of the REESS
The procedure starts with the discharge of the
REESS of the vehicle while driving on the test
track at a steady speed of 70 per cent ± 5 per cent
of the maximum speed of the vehicle during 30
minutes. Pre-discharge activation and Post
discharge deactivation, if required, shall be
performed as per manufacturer guidelines.
Discharging is stopped:
(a) When the vehicle is not able to run at 65 per
cent of the maximum thirty minutes speed, or
(b) When an indication to stop the vehicle is
given to the driver by the standard on-board
instrumentation, or
(c) After having covered the distance of 100 km.
After discharging is stopped, process of
determining hydrogen emissions should be
started.
Component Based Test

REESS preparation
The ageing of REESS shall be checked, to
confirm that the REESS has performed at least 5
standard cycles (as specified in Annex 8,
Appendix 1).
Initial mechanical charge of the REESS
The mechanical charge is carried out:
(a) As per manufacturer guideline

44

(b) In an ambient temperature between 293 K
and 303 K.
Discharge of the REESS
The REESS is discharged at 70 per cent ±5 per
cent of the nominal power of the system.
Stopping the discharge occurs when minimum
SOC as specified by the manufacturer is
reached.
After discharging is stopped, process of
determining hydrogen emissions should be
started.
Annex
9 -
Append
ix 1



Annex
9G
OVERCHARGE PROTECTION OVERCHARGE PROTECTION (Applicable
only for electrically chargeable REESS)
Annex
9H - 3.2
Discharging
At the beginning of the test, all relevant main
contactors shall be closed.
A constant current discharge shall be performed
if applicable with at least 1/3 C rate but shall not
exceed the maximum current within the normal
operating range as specified by the
manufacturer.

45

A constant voltage discharge shall be performed
if applicable with at least standard discharge
voltage rate but shall not exceed the maximum
voltage within the normal operating range as
specified by the manufacturer.
The discharging shall be continued until the
tested-device (automatically) interrupts or limits
the discharging. Where an automatic interrupt
function fails to operate, or if there is no such
function then the discharging shall be continued
until the tested-device is discharged to 25 per
cent of its nominal voltage level or end point
power is reached as described by the
manufacturer.
Annex
9H - 3.3
Standard electrical or mechanical charge and
observation period
Directly after termination of the discharging the
tested-device shall be charged with a standard
electrical or mechanical charge as specified in
Annex 8, Appendix 1 if not inhibited by the
tested-device.
The test shall end with an observation period of
1 h at the ambient temperature conditions of the
test environment.
AIS038 SOC SOC or SOE











46

CHAPTER 6
6. Recommendations

India lacks energy storage standards that are agnostic to specific chemistries and technologies.
This poses a challenge for evaluating and integrating the diverse range of emerging
technologies. A range of Technical and Safety Parameters suitable for Chemistry Agnostic
Standards have been identified based on examination of existing standards. A draft template
for developing chemistry agnostic standards for energy storage has been developed in the BIS
format. This template can be utilized for development of standards & certifications. It is
recommended that BIS develops and notifies the use of these standards within a period of 3-4
months.
6.1 Modification of existing standards for application specific testing of emerging Energy
Storage technologies:
India's existing application standards for energy storage technology (like AIS038, IS039,
AIS040, AIS041, AIS048, AIS049, AIS156, AIS039, etc.) inherently impede certification of
emerging energy storage technologies (EST). The BIS needs to review and suitably modify the
standards, aligning them with the proposed modifications for facilitating application specific
testing and certification of the emerging Energy Storage technologies within a period of 3-4
months.

Additionally, Indian conditions require operation in ambient temperature of -20 to 60°C. The
following safety requirements need to be adhered to:

i. All technologies should ensure safety and accepted performance in these conditions.
ii. In case technologies cannot inherently function safely with acceptable performance in
these conditions, additional thermal management systems need to be mandated.

6.2 Quality and Standards for Connectivity to the Grid:
CEA Safety Standards and CEA (Technical Standards for Connectivity to the Grid)
Regulations needs to be suitably updated to cover ESS and other technologies like electrolysers
for Green Hydrogen. The Technical Standards may also cover the ‘Performance Standards’ for
different services as well as ‘Operation and Maintenance Standards’ for ESS facilities.

6.3 Establishing the Testing Infrastructure for Emerging Energy Storage Technologies:
India's energy storage sector, vital for clean energy integration, suffers from a lack of
centralized testing infrastructure data base. This fragmentation leads to unreliable data, hinders
innovation due to inconsistent testing protocols, and limits collaboration due to a lack of
transparent data sharing. More so, existing central testing and certification agencies, such as

47

International Centre for Automotive Technology (ICAT) and Automotive Research
Association of India (ARAI) under the Ministry of Heavy Industries (MHI), lack the
necessary equipment and facilities to handle the full range of technical parameters associated
with evolving energy storage technologies. This translates to inaccurate and incomplete testing,
hindering the development and commercialization of reliable storage solutions.

Upgrading existing testing facilities and establishing new ones require significant resources.
By leveraging government resources and private sector expertise, PPPs can facilitate the
establishment of high-end testing infrastructure. This collaborative approach ensures
efficient resource allocation and faster development of the testing infrastructure, enabling India
to keep pace with the rapid advancements in energy storage technologies.

It is recommended that BIS needs to establish a centralized testing infrastructure dashboard
for infrastructure, equipment’s, type of test, timelines, testing process, fee, trained manpower,
online application, testing tracking, result and certification to facilitate the energy storage
manufacturers, startups, innovators etc.

6.4 Capacity Building:

Developing a skilled workforce through targeted training programs for personnel by BIS in co-
ordination with the different user ministries (MHI, Power, MNRE, Transport etc.) in these
centralized facilities is essential. This ensures expertise in handling the intricacies of diverse
energy storage technologies. By investing in capacity building via these partnerships, India can
create a robust ecosystem that fosters innovation and development in the crucial energy storage
sector. This, in turn, will unlock the true potential of clean energy integration, paving the way
for a sustainable energy future.

6.5 The Template for Chemistry Agnostic Standards has been developed as below that can be
utilised by BIS in developing the standards:

Template for Chemistry Agnostic Standard
Part I Metal Air Flow Battery
Part II Metal ion, Metal Sulfur and Lead acid
Part III Fuel cells
Part IV Pumped Hydro
Part I of the standard is as below. This template may be used to develop the other parts of the
standard.
CONTENTS
1. Scope
2. Normative references

48

3. Terms and definitions
4. Abbreviated terms
5. Nomenclature
6. Descriptive overviews of the flow battery
6.1.Indicative Diagram of a metal air flow battery (MAFB)
6.2.Component descriptions of a MAFB
7. General Test conditions
7.1.Accuracy of measuring instruments
7.1.1. Voltage measurement
7.1.2. Current measurement
7.1.3. Power measurement
7.1.4. Electric energy measurement
7.1.5. Temperature measurement
7.1.6. Mass measurement
7.1.7. Time measurement
7.2. Ambient temperature
7.3.Ambient Humidity
8. General Test procedures for performance
8.1. Determination of maximum deliverable output power
8.2. Determination of maximum input auxiliary power
8.3. Determination of energy capacity density
8.4.Determination of energy capacity density during Standard Discharge
8.5.Determination of energy capacity density during Peak Power Discharge
8.6. Determination of efficiency
9. Other general aspects
9.1.Identification labels and Markings
9.2.Electrical Specifications
10. Safety tests
10.1. Transport
10.1.1. Impact
10.1.2. Vibration
10.1.3. Climate temperature cycle
10.1.4. Leaving half used batteries
10.2. Misuse
10.2.1. Crush test
10.2.1. External short circuit
10.2.2. Over discharge
10.2.3. Free fall
10.2.4. Reverse energy storage fluid flow direction
10.2.5. Nail penetration test
10.2.6. Reverse electrical loading
11. Transport, storage, disposal and environmental aspects
12. Packing and transport
13. Dismantling, disposal, and recycling

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14. Safety requirements and protective measures
14.1. General
14.2. Short-circuits
14.3. Hazards of gaseous emissions
14.3.1. General
14.3.2. Types of gases
14.3.2.1. Flammable gases
14.3.2.2. Corrosive gases
14.3.3. Ventilation
14.3.3.1. General
14.3.3.2. Natural Ventilation
14.3.3.3. Forced Ventilation
14.3.4. Warning sign
14.3.5. Close vicinity to emissions
14.4. Hazard posed by liquids
14.4.1. General
14.4.2. Detection of energy storage fluid leakage
14.4.3. Protective measures against leakage
14.5. Operational hazards and measures
15. General
16. Start
17. Remote monitoring and control systems
18. Protection
19. Auxiliary power source
19.1. Safety requirements for stacks
20. Sampling and Quality assurance
20.1. Sampling
20.2. Quality Plan
21. Example chemistries of metal air flow batteries
22. PROCEDURE FOR CONDUCTING A STANDARD CYCLE
Table 1 - Electrical Specifications
Table 2 Transport tests – Electrical, Environmental/Mechanical, Climatic temperature
Table 3 Misuse tests - Electrical, Environmental, Human mistake
Table 4 - List of verification tests for stacks for protective measurements
Table 5 - Example chemistries of metal air flow batteries
Figure 1 – Metal Air Flow battery (MAFB)
Figure 2 – Example of Crush test
1. Scope
This template standard relates to metal air flow battery (MAFB) that can be used in electrical
energy storage (EES) applications, automobiles and provides the main terminology and general
aspects of this technology, including terms necessary for the definition of unit parameters, test
procedures, criteria for performance, environmental issues and ensure safety of Metal air flow

50

batteries under intended use and reasonably foreseeable misuse. It also includes the description
of MAFB.
2. References
Different tests, definitions and terminologies have been referred from following standards: IEC
62392-1, IEC 62392-2-1, IEC 62392-2-2, IS 6303-1, IEC 60086- 2, IEC 60086-5
3. Terms and definitions
3.1. Activation
Transition of MAFB from either OFF state or cold standby to ON state.
3.2. Activation time
The duration between the transition of MAFB from either OFF state or cold standby to ON
state.
3.3. Air
Air is referring to the mixture of gases comprising of oxygen which is one of the reactants in
the metal air flow battery's electrochemical reactions.
3.4. Air filter
A component designed to remove particulate matter and contaminants from the air before it
enters the metal air flow stack enclosure
3.5.Air piping
A network of tubes or hoses used to circulate air back and forth between atmosphere to metal
air flow stack enclosure. It may include various pipes, connectors, and other components that
ensure the proper delivery of air to the enclosure
3.6.Air pump
A device used to circulate air back and forth between atmosphere to metal air flow stack
enclosure.
3.7.Ambient temperature
Environmental temperature around a metal air flow battery
3.8. Auxiliary energy
Energy consumed by all the auxiliary equipment and components of the metal air battery
support unit.
3.9.Average Discharge Duration
Average time on discharge which shall be met by a sample of batteries



51

3.10. Cold standby
State of MAFB in which no electrical power/energy is supplied from the POMC (Point of Main
connection) to the external load and the MABSU is partially active to perform required
functions
3.11. Control Unit
Electronic unit associated with a metal air flow battery which monitors and/or manages its
state, calculates secondary data, reports that data and/or controls its environment to influence
the metal air flow battery’s performance, state of energy and/or service life
3.12. Discharge
Operation during which a metal air flow cell/ stack when connected to an external electrical
circuit results in electrochemical changes within the cell and releases electrical energy in that
external electrical circuit
3.13. End of Discharge
End of discharge limit conditions specified by the manufacturer at which a discharge is
terminated
3.14. Enclosure
The part enclosing the internal units and providing protection against direct contact from any
direction of access
3.15. Effective Electrical Output Power
Electrical power output at the POMC (Point of Main connection) less by the electrical power
input at the POAC (Point of Auxiliary Connection) of the MAFB
3.16. Efficiency
Effective Electrical Output Power per unit of electrical power output at the POMC of the
MAFB
3.17. Electrode
The conducting body that contains active materials and through which current enters or leaves
a metal air flow cell
3.18. Energy storage fluid
Fluid that contains active materials and flows through the metal air flow cell/stack, consisting
of liquid, suspension or gas
3.19. Energy storage fluid piping
A network of tubes or hoses used to circulate energy storage fluid back and forth between fluid
tank and metal air flow stack enclosure. It may include various pipes, connectors, and other
components that ensure the proper and safe delivery of fluid to the enclosure

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3.20. Energy storage fluid pump
A device used to circulate energy storage fluid back and forth between energy storage fluid
tank and metal air flow stack enclosure
3.21. Energy storage fluid tank
Storage chamber for energy storage fluid. Its design should be at least IP65-compliant
3.22. End point Power
Specified value of the output power of the MAFB at which standard discharge is terminated
3.23. Energy Capacity (Wh)
The total amount of electrical energy that can be stored in a metal air flow cell
3.24. Energy Capacity density
The total amount of 2electrical energy that can be stored in the MAFB per unit weight of metal
anode
3.25. Fluid leakage
Unplanned escape of fluids from a metal air flow cell, stack or MAFB
3.26. Fluid system
Components and equipment destined to store and circulate energy storage fluids, such as tanks,
pipes, manual valves, electrical valves, pumps and sensors
3.27. Forced ventilation
Movement of air and its replacement with fresh air by mechanical means
3.28. Fully discharged
Condition (status) where, after a discharge process as specified by the manufacturer, the metal
air flow battery reaches the end of discharge point
3.29. Gas release
Emission of gas from the metal air flow battery to the environment
3.30. Heat exchanger
A device designed to exchange heat between the metal air flow battery and its surroundings,
helping to maintain an optimal temperature range for efficient operation and safety.
3.31. Hot standby
State of MAFB in which no electrical power/energy is supplied from the POMC to the external
load and the MABSU is fully active to perform required functions.


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3.32. Input Auxiliary power
Electrical power supplied to all the auxiliary equipment and components of the MABSU
3.33. Interlock
Circuit linking mechanical, electrical or other devices intended to make the operation of a piece
of apparatus dependent on the condition or position of one or more others.
3.34. Maximum ambient temperature
Highest ambient temperature at which the MAFB is operable and should perform according to
specified requirements
3.35. Maximum input auxiliary power
Highest level of power in watt that can be supplied to the MABSU and at which it is operable
and performs according to specified conditions
3.36. Maximum output power
Highest level of power in watt that can be supplied by the MAFB and at which it is operable
and performs according to specified conditions
3.37. Metal
The metal used as anode (negative electrode) can be made up of but not limited to metals like
Aluminium, Iron, Lithium, Zinc and their alloys. In case of Aluminium, it should be compliant
with EN 481-1, EN485-2, EN515, EN573-2.
3.38. Metal air battery support unit (MABSU)
Auxiliary units, such as heat exchanger, ventilation system, safety system, and control unit
used in an MAFB, and which are not stacks and not power conversion system
3.39. Metal air flow cell
A cell characterized by the spatial separation of the electrodes and the movement of the energy
storage fluids
3.40. Metal air flow battery (MAFB)
Two or more metal air flow cells electrically connected including all components for use in
electrochemical energy unit such as metal air battery support unit and stack
3.41. Minimum ambient temperature
Lowest ambient temperature at which the MAFB is operable and should perform according to
specified requirements.
3.42. Natural ventilation
Movement of air and its replacement with fresh air because of wind and/or temperature
gradients

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3.43. Negative terminal
Accessible conductive part provided for the connection of an external electrical circuit to the
negative electrode of the cell
3.44. Nominal Voltage
Suitable approximate value of voltage used to identify the voltage of a battery.
3.45. Non-operating state
State of the MAFB when it is not performing any required function
3.46. OFF-state
State of the MAFB when it is not delivering electrical energy/power at POMC
3.47. ON-state
State of MAFB when it is actively delivering electrical energy/power at POMC
3.48. Open circuit Voltage (OCV)
Voltage across the terminals of a metal air flow battery when no current is flowing
3.49. Operating state
State in which the MABF performs the required functions and includes the ON-state, hot
standby and cold standby states.
3.50. Operational condition
Activity or status where all the different elements of a complex activity such as electrochemical
changes and MABSU are brought into a harmonious and efficient relationship.
3.51. Output power
Electrical power supplied by the metal air flow battery during discharge.
3.52. Point of auxiliary connection (POAC)
Reference point where the MABSU is connected to an external power source.
3.53. Point of auxiliary measurement (POAM)
Physical location in the MABSU where the energy absorbed from the external power source is
to be measured/recorded
3.54. Point of main connection (POMC)
Reference point where the MAFB is connected to the final application point.
3.55. Point of main measurement (POMM)
Physical location in the (MAFB) circuit where the energy delivered from the stack is to be
reproducibly measured/recorded

55

3.56. Positive terminal
Accessible conductive part provided for the connection of an external electrical circuit to the
positive electrode of the cell
3.57. Rated energy
Manufacturer declared value of the energy content of the MAFB when discharged under
specified (rated) conditions and measured at the POMM.
3.58. Rated input auxiliary power
Manufacturer declared value of input auxiliary power for a specific set of operating conditions
of the MAFB and measured at the POAM.
3.59. Rated maximum Output power
Manufacturer declared highest output power level that the MAFB can deliver.
3.60. Rated output power
Manufacturer declared value of output power for a specific set of operating conditions of the
MAFB
3.61. Routine test
Conformity test made on each individual item during or after manufacture
3.62. Sensor
Device which detects/ measures a physical property and records, indicates or responds to it
3.63. Service life
Duration from the time of MAFB commissioning test to the end of service life
3.64. Short circuit current
Maximum current which should be delivered by a MAFB into an external circuit with zero
electrical resistance, or an external circuit which depresses the cell or battery voltage to
approximately 0 volt.
3.65. Shutdown
Regulated or instantaneous shutdown of a MAFB triggered by the shutdown of the end
application system, internal or external protection systems, or manual intervention.
3.66. Stack
Group of metal air flow cells, assembled in a contiguous form and usually connected
electrically in series



56

3.67. Standard Discharge
A constant voltage discharge of a metal air flow cell/stack at standard discharge voltage as
declared by the manufacturer.
3.68. Standard Discharge voltage
The voltage declared by the manufacturer at which standard discharge of a metal air flow
cell/stack is to be carried out.
3.69. Standby state
State of MAFB in which no electrical power is supplied from the POMC to the external load
and the MABSU is partially or fully active to perform required functions
3.70. State of energy
The remaining energy as a percentage of the maximum available energy under operating
conditions as declared by the manufacturer.
3.71. Type test
Conformity test made on one or more items representative of the production.
4. Abbreviated terms
MABSU Metal air battery support Unit
MAFB Metal air flow battery
POAC Point of auxiliary connection
POAM Point of auxiliary measurement
POMC Point of main connection
POMM Point of main measurement

5. Nomenclature
Refer Annexure C (Clause 4.1.5) of IS 6303-1

6. Descriptive overview of the Metal Air Flow Battery

6.1.Indicative Diagram of a metal air flow battery (MAFB)

57



Figure 1 – Metal Air Flow battery (MAFB)
6.2.Component description of metal air flow battery (MAFB)
1. Stack
1. Electrodes
2. Enclosure
2. Metal air Battery support Unit (MABSU)
1. Pump
2. Tank
3. Piping
4. Air and air filter
5. Sensors
1. Energy storage fluids
7. Heat exchanger
8. Control Unit

7. General test conditions
7.1.Accuracy of measuring instruments
7.1.1. Voltage measurement
The instruments used shall be of an accuracy class equal to 0.5% or better. The internal
resistance of the voltmeter used shall be at least 1 kohm/V.

7.1.2. Current measurement
The instruments used shall be of an accuracy class equal to 0.5% or better.


7.1.3. Power measurement
The instruments used shall be of an accuracy class equal to 0.5% or better.

7.1.4. Electric energy measurement
The instruments used shall be of an accuracy class equal to 1% or better.

7.1.5. Temperature measurement

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The instruments used shall have a resolution of 0.5 K and the accuracy of the
instruments shall be +0.5K or better.
7.1.6. Mass measurement
The instruments used shall have a resolution of 1 gram and accuracy of the instruments
shall be +1 gram or better.

7.1.7. Time measurement
The instruments used shall have a resolution of 1s and the accuracy of the instruments
shall be 1% of the measured time interval or better.

7.2. Ambient temperature
All tests of a MAFB shall be carried out at an ambient temperature of 27 °C + 2 K unless
otherwise specified in a test clause or agreed by the manufacturer and user. The ambient
temperature shall be measured and reported.

7.3. Ambient Humidity
All tests of a MAFB shall be carried out at relative humidity of 60 ± 5 percent RH unless
otherwise specified in a test clause or agreed by the manufacturer and user. The ambient
humidity shall be measured and reported.


8. General Test procedures for performance
8.1.Determination of maximum deliverable output power
8.1.1. General
The maximum deliverable output power is affected by the discharge voltage, temperature, and
the auxiliary power needs for the MAFB operation. Any maximum deliverable output power
value determined is hence representative or applicable only to the specific operation condition
of the MAFB.
The manufacturer's recommended procedures should be followed during metal air flow cell or
battery preparation.


8.1.2. Test procedures
The test for determining the maximum deliverable output power shall be in accordance with
the following procedures:
A Constant Voltage (CV) discharge shall be carried out at the POMC of the MAFB.
The conditions of all the components of the MABSU should be noted and as declared by the
manufacturer in the ON state. The MABSU shall be supplied by a separate power source. The
rating of the power source shall be greater than the maximum receivable input auxiliary power
as declared by the manufacturer.
The voltage level selected for CV discharge is the voltage of a metal air flow cell multiplied
by number of cells in series in the MAFB.

59

The test unit shall be discharged at constant voltage steps with each step of 5 minutes starting
from Open circuit voltage to 0.2V multiplied by number of cells in series of the MAFB. The
step size/interval shall be equal to 0.1V multiplied by number of cells in series of the MAFB.
The total time duration of the discharge shall be recorded. The voltage level at each step shall
be kept constant to within ±0.5 % of the set value.
The ambient temperature of the MAFB shall be maintained at a constant temperature of 27 °C
+ 2 K. The points within the MAFB indicative of the MAFB temperature shall be declared by
the manufacturer and temperature at these points shall be recorded during the test.
The maximum deliverable output power value and voltage at the POMM and the corresponding
auxiliary power supplied shall be recorded. The maximum deliverable output power value shall
be accompanied with the corresponding voltage at the POMM and temperature of the MAFB.

8.2.Determination of maximum input auxiliary power
8.2.1. General
The maximum input auxiliary power is affected by the operating state, temperature, voltage
and delivered output power of the MAFB. Any maximum input auxiliary power value
determined is hence representative or applicable only to the specific operation condition of the
MAFB.
The manufacturer's recommended procedures should be followed during metal air flow cell or
battery preparation.
8.2.2. Test procedure
The test for determining the maximum input auxiliary power shall be in accordance with the
following procedures:
A Constant Voltage (CV) discharge shall be carried out at the POMC of the MAFB.
The conditions of all the components of the MABSU should be noted and as declared by the
manufacturer in the ON state. The MABSU shall be supplied by a separate power source. The
rating of the power source shall be greater than the maximum input auxiliary power as declared
by the manufacturer.
The voltage level selected for CV discharge is the voltage at which the maximum deliverable
output power is recorded.
The test unit shall be discharged at constant voltage for 5 minutes during which the voltage
shall be kept constant to within ±0.5 % of the set value.
The ambient temperature of the MAFB shall be maintained at a constant temperature of 27 °C
+ 2 K. The points within the MAFB indicative of the MAFB temperature shall be declared by
the manufacturer and temperature at these points shall be recorded.
The maximum input auxiliary power value at the POAM, delivered output power, current and
voltage at the POMM and the corresponding auxiliary power supplied shall be recorded. The
maximum input power value shall be accompanied with the corresponding voltage, delivered
output power at the POMM and temperature of the MAFB.






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8.3.Determination of energy capacity density
8.3.1. Determination of energy capacity density during Standard Discharge
8.3.1.1. General
This test is for determining the energy capacity density of the MAFB by measuring the total
discharge energy output from the MAFB during standard discharge per unit weight metal
anode.
The manufacturer's recommended procedures should be followed during metal air flow cell or
battery preparation.
8.3.1.2. Test procedures
The test for determining the energy capacity shall be in accordance with the following
procedures:
The total weight of the metal anode in each metal air flow cell/stack of the MAFB shall be
measured before test.
A Constant Voltage (CV) discharge shall be carried out at the POMC of the MAFB at standard
discharge voltage as declared by the manufacturer.
The conditions of all the components of the MABSU should be noted and as declared by the
manufacturer in the ON state. The MABSU shall be supplied by a separate power source. The
rating of the power source shall be greater than the maximum input auxiliary power as declared
by the manufacturer.
The standard discharge voltage at the POMC shall be kept constant to within ±0.5 % of the set
value throughout the duration of the test.
The delivered output power, current and voltage at the POMM shall be recorded in intervals of
1 second.
The test shall be carried out till the delivered output power falls to the end point power as
declared by the manufacturer.
The energy capacity is the time summation/integration of the output power till end of point
power. The energy capacity density is obtained by dividing the energy capacity with the total
metal anode weight in kg.
The energy capacity shall be accompanied with the corresponding standard discharge voltage
and maximum output power at POMM, end point power and temperature of the MAFB.
The ambient temperature of the MAFB shall be maintained at a constant temperature of 27 °C
+ 2 K. The points within the MAFB indicative of the MAFB temperature shall be declared by
the manufacturer and the temperature at these points shall be recorded during the test.

8.3.2. Determination of energy capacity density during Peak Power Discharge
8.3.2.1. General
This test is for determining the energy capacity density of the MAFB by measuring the total
discharge energy output from the MAFB during peak power discharge per unit weight metal
anode.
The manufacturer's recommended procedures should be followed during metal air flow cell or
battery preparation.
8.3.2.2. Test procedures
The test for determining the energy capacity shall be in accordance with the following
procedures:

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The total weight of the metal anode in each metal air flow cell/stack of the MAFB shall be
measured before test.
A Constant Voltage (CV) discharge shall be carried out at the POMC of the MAFB at the
maximum deliverable output power voltage point obtained in 8.1.
The conditions of all the components of the MABSU should be noted and as declared by the
manufacturer in the ON state. The MABSU shall be supplied by a separate power source. The
rating of the power source shall be greater than the maximum input auxiliary power as declared
by the manufacturer.
The standard discharge voltage at the POMC shall be kept constant to within ±0.5 % of the set
value throughout the duration of the test.
The delivered output power, current and voltage at the POMM shall be recorded in intervals of
1 second.
The test shall be carried out till the delivered output power falls to the end point power as
declared by the manufacturer.
The energy capacity is the time summation/integration of the output power till end of point
power. The energy capacity density is obtained by dividing the energy capacity with the total
metal anode weight in kg.
This energy capacity shall be accompanied with the corresponding discharge voltage and
maximum output power at POMM, end point power and temperature of the MAFB.
The ambient temperature of the MAFB shall be maintained at a constant temperature of 27 °C
+ 2 K. The points within the MAFB indicative of the MAFB temperature shall be declared by
the manufacturer and the temperature at these points shall be recorded during the test.

8.4. Determination of efficiency
8.4.1. General
The efficiency of the MAFB is affected by the delivered output power and the input auxiliary
power consumption during the discharge of the MAFB. Any energy efficiency determination
is hence representative or applicable only to the MAFB at the specified power levels.
The temperature and conditions of the MABSU shall be recorded and reported.
The manufacturer's recommended procedures should be followed during metal air flow cell or
battery preparation.
8.4.2. Calculation
Effective maximum output power = (maximum deliverable output power - maximum input
auxiliary power)
EPMAX = (Effective maximum output power)/ (maximum deliverable output power)
Where EPMAX is the maximum efficiency obtained at maximum deliverable output power at a
constant MAFB ambient temperature of 27 °C + 2 K.

9. Other general aspects
9.1.Identification labels and Markings
9.1.1. Name plate information
The name plate/label(s) shall include the following information:
a) manufacturer's name,

62

b) serial number (optional),
c) date of commissioning (optional),
d) maximum DC voltage(V), current(A) and power(kW) in operation,
e) rated energy capacity density (kWh/kg),
f) transport weight (kg) (optional),
g) chemical type of battery (active materials shall be indicated),
9.1.2. Warning label information and location
The warning labels shall be placed at such a position that they are visible from any direction of
approach to the MAFB where hazards can be present. The safety symbols and possibly
associate information shall be explained and/or included in the MAFB instruction manual.
9.2. Electrical Specifications
Table 1 Electrical Specifications
Electrical Specifications Values
Open Circuit Voltage 1.50 V -2.30V
End point Power 0.01*P0max
Nominal Voltage 1.20 V
Energy Capacity Density Greater than 1500 Wh/kg of metal anode at standard
discharge Voltage
Activation time < 1min
Standard discharge Voltage 1.20 V
Average Discharge Duration Greater than 0.6*t hours at standard discharge voltage
*Above values are for Aluminum air flow battery
Where t is thickness of metal anode in mm for prismatic metal air flow cell, P0max is maximum
deliverable output power
10. Safety Tests
10.1. Transport
Table 2 Transport
Test Intended use simulation Requirements Procedure Reference
Electrical test Storage after partial use
No leakage, No fire,
No explosion
IEC 60086-5, Clause
6.3.2.1
Environmental/
Mechanical tests
Transportation - Shock
No leakage, No fire,
No explosion
AIS-156, Clause 6.4.2
and Annex 8D
Transportation - Vibration
No leakage, No fire,
No explosion
AIS-156, Clause 6.2 and
Annex 8A

63

Climatic-
temperature Climatic-temperature cycling
No leakage, Nofire,
No explosion
IEC 60086-5, Clause
6.3.2.4
10.2. Misuse
Table 3 Misuse
Test Intended use simulation Requirements
Procedure Reference
Electrical test
Incorrect Installation No fire, No explosion
IEC 60086-5, Clause
6.4.2.1
External short circuit No fire, No explosion
IEC 60086-5, Clause
6.4.2.2
Over discharge No fire, No explosion
IEC 60086-5, Clause
6.4.2.3
Environmental
test
Free fall No fire, No explosion
IEC 60086-5, Clause
6.4.2.4
Nail penetration test No fire, No explosion AIS 048, Clause 2.2.4
Crust test No fire, No explosion
IEC 62660-2, Clause
6.1.3
Human mistake
Reverse energy storage
fluid flow direction No fire, No explosion



10.2.1. Crush Test
The test is performed to characterize cell responses to external load forces that may cause
deformation. The test shall be performed as follows.
a) Perform the test at 100% State of Energy of cell.
b) The cell shall be placed on an insulated flat surface and be crushed with a crushing tool
of round or semiconductor bar, or sphere or hemisphere with a 150mm diameter. It is
recommended to use the round bar to crush a cylindrical cell, and the sphere for a
prismatic cell. The force for the crushing shall be applied in direction nearly
perpendicular to a layered face of positive and negative electrodes inside cell. The
crushing tool shall be selected so that the cell is deformed nearly in proportion to the
increase of crushing force.
c) The force shall be released when a deformation of 15% or more of initial cell dimension
occurs, or the force of 20 times the weight of cell applied. The cells remain on test for
24 h.

64


Figure 2 - Example of Crush test
11. Transport, storage, disposal and environmental aspects
11.1. Packing and transport
For protection against hazards, appropriate measures shall be taken, such as emptying
the fluids from the stack or discharging before transportation, proper insulation of
terminals and other protective measures as specified by the manufacturer to avoid any
hazardous chemical changes during packing and transportation.
11.2. Dismantling, disposal, and recycling
For dismantling, disposal and recycling follow manufacturer guidelines.
12. Safety requirements and protective measures
12.1. General
The metal air flow battery differs from other batteries, in that a system for circulating the
energy storage fluid is present. The fluid circulating system consists of tanks, pumps,
piping, sensors and some safety-relevant devices.
From a chemical safety point of view, since fluid is contained in tanks, pipes and stacks,
the sealing is an important factor. If there is also a possibility of any gaseous emissions as
declared by the manufacturer, appropriate countermeasures shall be implemented.
12.2. Short-circuits
The electrical energy stored in an MAFB can be released in an uncontrolled manner due to
short-circuiting the terminals. Because of its considerable level of energy and subsequent
high current, the heat generated can melt metal, produce sparks, cause explosion, or
vaporize fluid.
To avoid short-circuits protective devices such as insulation shrouds, fuses and circuit
breakers shall be installed in a way that a short-circuit does not occur under any foreseeable
conditions.

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• For protective measures, the MAFB may mitigate a short-circuit fault which occurs
outside stacks by stopping the supply of energy and fluids to the metal–air flow battery
cells;
• stopping power conversion system and opening circuit breaker(s); and,
• interrupting the short-circuit current path by using fuses between stacks.
It is suggested that each stack has a fuse to break the short-circuit path. Specific location and
quantity of fuses and/or circuit breakers shall be decided between the manufacturer and the
system user in consideration of cell protection and system safety.
12.3. Hazards of gaseous emissions
12.3.1. General
Metal-air Flow batteries can produce gases in small quantities that can be flammable and/or
corrosive in nature. The quantities produced depend on the operating conditions of the MAFB
and their release to the environment shall be managed with adequate safety features (e.g.
ventilation, absorption traps, scrubbers).
The gas emission and its mitigation shall be considered in the metal air flow battery design
process. It is suggested to install necessary gas monitoring equipment with alarms and
appropriate interlocks.
12.3.2. Types of gases
12.3.2.1. Flammable gases
The risk level of flammable gases increases if the following hazards coincide:
• accumulation of combustible gases,
• their mixture with oxygen,
• presence of ignition sources.
The MAFB shall have protective measures against the above hazards, including but not limited
to:
• reduction in the generation and dilution of combustible gases,
• prevention of diffusion of gases outside the volume where they are generated
• elimination of ignition sources
12.3.2.2. Corrosive gases
The risk level of corrosive gases increases if the following hazards coincide:
• generation and accumulation of corrosive gases,
• human access to the vicinity of corrosive gases.
The MAFB shall have protective measures against the above hazards, including but not limited
to:
• Construction of the system with corrosion-resistant material
• elimination and dilution of corrosive gases,

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• collection of toxic gases by a scrubber
• limitation of human access.

12.3.3. Ventilation
12.3.3.1. General
The manufacturer shall specify the ventilation requirements for the compartment where the
MAFB is installed. This specification shall involve the warning signs, operator access
limitation, mitigation of static discharges, numbers of air exchanges in m
3
/h required air flow
patterns and exhaust direction. The safety requirements and procedures for personnel and user
handling shall be specified. The manufacturer shall provide data and a measurement method
used to determine the gas emission rating, and ventilation measures shall be implemented.
Ventilation is required to ensure the necessary thermal management and that no combustible
or harmful gases reach a critical concentration level. The ventilation requirement shall be met
by either one or a combination of the following methods:
• natural ventilation
• forced ventilation through the room or enclosure.
12.3.3.2. Natural ventilation
When natural ventilation is used, battery rooms or enclosures shall be equipped with an inlet
and an outlet for the air with a minimum free opening area which meets the ventilation
requirements.
12.3.3.3. Forced ventilation
When forced ventilation is used, gases which are released from the MAFB into the room or
enclosure shall be expelled to the atmosphere using a ventilation system, which may combine
an opening and fan. If forced ventilation is essential for the safe operation of the MAFB, then
an appropriate interlock shall prevent its operation when the forced ventilation is not operating
or has failed.
12.3.4. Warning sign
Appropriate warning signs which prohibit sparks, smoking, open flame, and electrostatic
discharges shall be placed at the entrance of the hazardous area.
12.3.5. Close vicinity to emissions
The dilution of gases is not always fully achieved in the close vicinity of the exhaust of released
gases or at the outlet of direct forced ventilation, therefore a safety distance from the outlet
shall be observed. The dispersion of gases depends on the gas emission rate and the type of
ventilation close to the source of emission.




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12.4. Hazard posed by liquids
12.4.1. General
The impact of the energy system fluid involved in the MAFB leakage can be categorized in
terms of toxicity, corrosiveness, environmental impacts, and flammability.
Since the energy storage fluids are flowing through the fluid system, there is a possibility that
a leakage will continue unattended or unmitigated if the detection of the leakage and/or the
protection against the leakage are inappropriate. In addition, fluids supplied to the stacks may
be stored in the common tank in a large volume while:
• ensuring the sealing performance of the fluid system,
• incorporating corrosion resistance in the design and the material of the parts that come
into contact with the energy storage fluids,
• detecting leakage and taking appropriate measures,
• preventing leakage to the surroundings, and,
• providing information and markings concerning the fluid.
12.4.2. Detection of energy storage fluid leakage
Leakage shall be detected by appropriate protection measures such as a leakage sensor. The
detection and protective functions shall be verified appropriately.
The detection of the fluid shall initiate the necessary countermeasures such as stopping the
pumps and closing the valves.
12.4.3. Protective measures against leakage
The MAFB must have a leakage collection provision such as a collecting tray (also known as
collecting basin) under the tanks which is stable to the energy storage fluid and has a volume
at least equal to the largest tank of the MAFB. Refer to the local safety regulations for other or
additional protective measures.
12.5. Operational hazards and measures
12.5.1. General
When the MAFB is designed to work with other equipment upstream and/ or downstream, such
as control centre upstream, a signal interface or other means shall be provided to enable a
coordinated operation, including start, stop, emergency shutdown and discharge.
Improper integration can cause unintentional operation which potentially leads to a hazardous
situation.
Proper coordinated operation shall be confirmed by appropriate methods.
12.5.2. Start
The MAFB shall be started only when the starting condition is achieved through ensuring that:
• all safeguards are in place and are functional,
• the safety conditions have been fulfilled for restart after a stop,

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• non-hazardous conditions are verified for intentional restarting actuation,
• suitable interlocks are provided for correct sequential starting.

12.5.3. Remote monitoring and control systems
An MAFB that can be operated remotely shall have a local, labelled switch or other means to
disconnect the system from remote signals that may be used while a local operator performs
inspection or maintenance.
The implementation of a remote monitoring system shall be considered in order to check if the
system is operating safely. The data collected automatically from the MAFB inquiry can help
to evaluate its state of health and the remaining life of its components. Diagnosis is performed
by monitoring the change of capacity or changes in the measured parameters. These data can
be transmitted through an information network in a timely manner.
12.5.4. Protection
The MAFB shall be equipped with appropriate protective devices to detect abnormal situations
and initiate an emergency stop.
12.5.5. Auxiliary power failure
In case of an auxiliary power failure to the MABSU, the MAFB shall be designed in such a
way to ensure safe shutdown of the system. This may include:
• necessary detection of loss of power in the MAFB,
• the trigger of an alarm informing on the situation at the designated terminal,
• initiation of a proper designated shutdown including separation from the POMC, and
• stopping of the pumps and closing of the designated valves
As an example, this can be facilitated through integrating a UPS for supporting the Control
Unit operation and/or supplying power from a separate secure source.
12.6. Safety requirement for stacks
The tests of stacks described below shall be carried out in order to ensure safety.
Table 4 - List of verification tests for stacks for protective measurements
Test Test category Test object Acceptance criteria
External Short circuit Type test Stack The test is passed if there is no fire,
explosion, or fluid leakage.
Heat shock strength Type test Stack There shall be no visible fluid
leakage.
Leakage Routine test Stack There shall be no visible fluid
leakage.


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13. Sampling and Quality assurance
13.1. Sampling
Refer Clause 7 of IS 6303-1
13.2. Quality plan
The manufacturer shall prepare and implement a quality plan that defines procedures for the
inspection of materials, components, cells and batteries and which covers the whole process of
producing each type of cell or battery. Manufacturers should understand their product
capabilities and should institute the necessary controls as they relate to product safety.

14. Example chemistries of metal air flow batteries

Table 5 - Example chemistries of metal air flow batteries
S. No. Negative electrode Energy storage fluid Positive electrode
1 Aluminium (Al) Alkaline aqueous

Air
2 Zinc (Zn) Alkaline aqueous Air
3 Iron (Fe) Alkaline aqueous Air
4 Li (Li) Non aqueous Air

15. PROCEDURE FOR CONDUCTING A STANDARD CYCLE
A standard cycle will start with a standard discharge followed by a standard electrical or
mechanical charge, whichever applicable.
Standard Discharge:
Discharge rate: The discharge procedure including termination criteria shall be defined
by the manufacturer.
Discharge with 1C current if Constant Current (CC) discharge is
applicable. If Constant Voltage (CV) discharge is applicable, then it
should be discharged at the standard discharge voltage.

Discharge limit (end
voltage or end power or
end current):
Specified by the manufacturer

70

Rest period after
discharge:
Minimum 30 min


Standard Charge:
Standard Electrical
charge:
The charge procedure including termination criteria shall be defined
by the manufacturer.
Charge with C/3 current if Constant Current (CC) charge is
applicable. If Constant Voltage (CV) charge is applicable, then it
should be charged at the standard charge voltage.

Standard Mechanical
charge:
Specified by the manufacturer










71

Annexure-I



72










73

Annexure-II






74








75

Annexure-III



76




77




78



79



80




81




82




83




84




85




















86

Annexure-IV









87


88







89








90

Annexure-V



91



92

















93

Annexure VI

References of Table 15: Ranges of Chemistry Agnostic Standards
[4]https://batteryuniversity.com/article/bu-205-types-of-lithium-ion
[5]https://www.batterydesign.net/sodium-ion-battery/
[6]https://batteryuniversity.com/article/bu-214-summary-table-of-lead-based-batteries
[7]https://www.sandia.gov/ess-ssl/wp-
content/uploads/2021/02/ESHB_Ch6_RedoxFlow_Small.pdf
[8]https://batteryuniversity.com/article/bu-216-summary-table-of-lithium-based-batteries
[9]https://docs.google.com/document/d/1Zdtl-
2OoSzegWTGr3ku6_62xZeAgUBKHLJOzOs6wf Lo/edit
[10]https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&cad=rja&uact=
8&ved=2ahUKEwjCzcrB7LaEAxWx4TgGHV5HBWcQFnoECCoQAQ&url=https://www.hy
drogen.energy.gov/docs/hydrogenprogramlibraries/pdfs/progress04/ivi3_borup.pdf&usg=AO
vVaw3PkX5jero3GIN8Icto8Tm2&opi=89978449
[11]https://electronics.stackexchange.com/questions/130580/what-is-a-safe-max-discharge-
rate-for-a-12v-lead-acid-battery
[12]https://www.indiamart.com/proddetail/hly-cell-26650-3-6v-5000mah-5c-battery-25a-
high-discharge-rate-battery-26891444797.html
[13] https://research.chalmers.se/publication/534781/file/534781_Fulltext.pdf
[14]https://www.sciencedirect.com/topics/earth-and-planetary-sciences/sodium-sulfur-
batteries
[15]https://batteryuniversity.com/article/bu-201-how-does-the-lead-acid-battery-work
[16]https://www.sciencedirect.com/topics/engineering/sodium-sulfur-battery
[17]https://thundersaidenergy.com/2023/11/02/redox-flow-batteries-for-the-duration/
[18]https://en.wikipedia.org/wiki/Sodium-ion_battery
[19]https://batteryuniversity.com/article/bu-409-charging-lithium-ion
[20]Study on Advanced Grid-Scale Energy Storage Technologies -Dept. of Hydro and
Renewable Energy IIT Roorkee Oct’23
[21]https://www.sciencedirect.com/science/article/pii/S2352484723012118
[22]https://www.indiamart.com/proddetail/hly-cell-26650-3-6v-5000mah-5c-battery-25a-
high-discharge-rate-battery-26891444797.html
[23]https://www.energy.gov/eere/fuelcells/articles/fuel-cells-fact-sheet
[24]https://web.iitd.ac.in/~sbasu/L5.pdf
[25]https://www.ineltro.ch/media/downloads/SAAItem/45/45958/36e3e7f3-2049-4adb-a2a7-
79c654d92915.pdf
[26]https://www.sciencedirect.com/science/article/abs/pii/S0306261915007473
[27]https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10300782/
[28]https://www.researchgate.net/publication/373643116_Operating_Lithium-
Sulfur_Batteries_in_an_Ultrawide_Temperature_Range_from_-50_C_to_70_C
[29]https://en.wikipedia.org/wiki/Fuel_cell
[30]https://www.sciencedirect.com/science/article/abs/pii/S0306261917315878