BESS Cooling Loop Plumbing SWMS
Safe work method statement for the installation of cooling loop plumbing on Battery Energy Storage Systems (BESS) including glycol handling, pressure testing, and working near high-voltage DC equipment.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Battery energy storage system (BESS) cooling loop plumbing covers the installation and maintenance of the liquid cooling loops that manage the temperature of grid-scale battery energy storage systems — the pipework, pumps, coolant and connections that circulate cooling fluid through the battery system. It is specialised plumbing at the intersection of plumbing and high-energy electrical systems, and the defining hazards are the proximity to the high-voltage, high-energy battery system, the coolant chemicals, the consequences of a coolant leak onto electrical equipment, and the thermal-runaway hazard of the batteries themselves. This document is written on the basis that BESS cooling loop plumbing is carried out by a licensed plumber under the BESS operator's electrical-safety and permit systems, with the electrical-proximity, coolant, leak and thermal controls in place.
BESS cooling loop plumbing is carried out in connection with the relevant parts of AS/NZS 3500 for the cooling pipework, integrated with the battery system under the operator's electrical-safety and permit systems. The proximity to the high-voltage, high-energy battery system is the defining hazard, with the coolant chemicals, the consequences of a leak onto electrical equipment, and the battery thermal-runaway hazard all critical. This document coordinates the electrical-proximity, coolant, leak, thermal and permit controls so the cooling loop plumbing is carried out safely.
Hazards identified
9 hazards covered, sorted by priority.
Electrocution, arc-flash and energy hazards near the battery system
Skin, eye and respiratory exposure to the coolant chemicals
Electrical fault, fire or hazard from coolant leaking onto electrical equipment
Thermal runaway, fire and toxic gas from the battery system
Coolant release under pressure from the cooling system
Atmospheric, restricted-access and gas hazards in the enclosures
Poisoning or fire from gases released by a battery fault
Non-compliance with the electrical-safety and permit systems
Musculoskeletal injury from the pipework and equipment
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Administrative: work under the BESS operator's electrical-safety and permit systems, with the battery system isolated or de-energised and made safe where required and the electrical-safety controls and safe approach distances applied.
- 2Administrative: have any work on or near the energised electrical system carried out under the electrical-safety system by or with the appropriate licensed electrical and competent personnel.
- 3Engineering: install and maintain the cooling loop to AS/NZS 3500 with leak-tight connections, and prevent and contain coolant leaks so coolant cannot leak onto electrical equipment.
- 4Administrative: manage the coolant chemicals to their safety data sheets, with skin, eye and respiratory protection and handling controls.
- 5Administrative: recognise and plan for the battery thermal-runaway, fire and toxic-gas hazard, with the operator's emergency arrangements, and apply the confined space controls and atmospheric testing in enclosed battery enclosures.
- 6Engineering: manage the stored pressure and energy of the cooling system, isolating and depressurising before the work.
- 7Engineering: use mechanical aids for the pipework and equipment, and confirm the cooling loop is leak-tight before the system is returned to service.
- 8Administrative: ensure the work is carried out and certified by an appropriately licensed plumber or gasfitter under the relevant state or territory plumbing and gasfitting licensing scheme, with the relevant competencies and a compliance certificate issued where required.
- 9Administrative: all workers must hold a valid White Card (General Construction Induction Training, CPCCWHS1001) where the work is construction work, with the plumbing, gasfitting, confined space and any other competencies required for the work.
- 10Administrative: conduct a pre-start toolbox talk covering the day's work, identified hazards, isolations, required PPE and emergency procedures, and record attendance in the consultation section.
- 11Administrative: consult workers and any health and safety representatives on the work and its risks, record the consultation, and keep this document available at the workplace.
- 12PPE: eye protection to AS/NZS 1337.1, hearing protection where required, gloves appropriate to the task, high-visibility clothing, and Class I or Class II safety footwear with protective toecap to AS/NZS 2210.3.
- 13Administrative: review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or health and safety representative raises a concern, when new hazards are identified, or at minimum every 12 months.
Applicable Codes of Practice
The plumbing and drainage standards for the cooling loop pipework.
Electrical safety and isolation for any electrical work, carried out by a licensed electrician.
Atmospheric testing, ventilation, entry permit and rescue controls where the work involves entry into a confined space.
Management of the chemicals used in the work, including safety data sheets and exposure controls.
The risk management process and hierarchy of controls applied to the hazards of the work.
High-Risk Construction Work triggered
BESS cooling loop plumbing is carried out on or near a high-voltage, high-energy battery system, bringing the work within this high risk construction work category and requiring a SWMS where it applies.
Battery energy storage system cooling loop plumbing is licensed plumbing work that, in the circumstances described, is high risk construction work — work carried out on or near energised electrical installations or services — so a SWMS must be prepared before the work commences, kept readily accessible, reviewed as necessary, and given to the principal contractor if one is appointed. The work is carried out to the relevant AS/NZS 3500 plumbing and drainage standards under the BESS operator's electrical-safety and permit systems, with the electrical-proximity, coolant, leak-containment and battery-thermal controls applied. Proximity to the high-energy battery system, a coolant leak onto electrical equipment, or a battery thermal-runaway event can cause electrocution, fire or serious injury, and breaches of the electrical and plumbing legislation and the primary duty of care under the model WHS Act are actively enforced, with offence categories running from failure-to-comply through to reckless conduct, and the most serious breaches carrying imprisonment for individuals. Body-corporate maxima are substantial and indexed; the current maximum follows the prevailing schedule of the responsible regulator.
Who this is for
- →Licensed plumbers installing and maintaining BESS cooling loops.
- →Plumbing and mechanical contractors working on battery storage cooling.
- →BESS and energy-storage installers and operators.
- →Energy and infrastructure PCBUs commissioning battery storage.
- →PCBU safety managers and supervisors coordinating the electrical-proximity, coolant and thermal controls.
What you receive
- ✓Editable Microsoft Word document (.docx) fully compatible with Microsoft Word 2016 and newer, Google Docs, and LibreOffice Writer.
- ✓Title page with editable fields for PCBU name, ABN, site address, project name, principal contractor details, and document revision date.
- ✓Hazard register with the battery energy storage system cooling loop plumbing hazards — each with a documented consequence, inherent risk rating on a 5x5 likelihood-consequence matrix, hierarchy-of-control measures, and residual risk rating.
- ✓BESS cooling loop prompts referencing AS/NZS 3500 and the operator's electrical-safety systems, an electrical-proximity and isolation section, a coolant and leak-containment section, and a battery-thermal and enclosure record.
- ✓Licensing, competency and permit prompts for the relevant plumbing, gasfitting, confined space and specialist work, and a respiratory protection selection and fit-test record per AS/NZS 1715 where relevant.
- ✓Worker consultation record per the model WHS Act consultation duty and a worker sign-on register (blank, expandable).
- ✓Applicable legislation and Codes of Practice schedule pre-populated for the model WHS jurisdiction with a state-variance reference table covering the harmonised states, plus Victoria.
- ✓Emergency procedure template and a revision log.
Worked example
A licensed plumber is engaged to install the cooling loop for a grid-scale battery energy storage system. The work is carried out under the BESS operator's electrical-safety and permit systems, with the battery system isolated or de-energised and made safe where required and the electrical-safety controls and safe approach distances applied. Any work on or near the energised electrical system is carried out under the electrical-safety system with the appropriate licensed electrical and competent personnel. The cooling loop is installed to AS/NZS 3500 with leak-tight connections, and coolant leaks prevented and contained so coolant cannot leak onto electrical equipment. The coolant chemicals are managed to their safety data sheets with skin, eye and respiratory protection. The battery thermal-runaway, fire and toxic-gas hazard is recognised and planned for with the operator's emergency arrangements, and the confined space controls and atmospheric testing applied in enclosed battery enclosures. The stored pressure and energy of the cooling system are managed. The cooling loop is confirmed leak-tight before return to service, and the records retained.
Related legislation
- Model Work Health and Safety Act — primary duty of care; the duty to consult workers; the reckless-conduct offence; and notifiable-incident provisions, as enacted in each jurisdiction.
- Model Work Health and Safety Regulations — Section 291 high risk construction work and the SWMS preparation and review duties, and the confined space, excavation and electrical provisions where applicable, as enacted in each jurisdiction.
- The relevant plumbing and drainage standards AS/NZS 3500 (Parts 0–5), AS/NZS 5601.1:2022 for gas, the AS 4032 valve standards, and the hazardous chemicals and electrical requirements, are called up by the state and territory plumbing, gas and safety legislation, together with the relevant network utility, healthcare and site requirements.
- Plumbing and gasfitting work is licensed under each state and territory's plumbing and gasfitting licensing scheme, with the relevant competencies for the specialist work, and compliance certification required for notifiable work; electrical work is carried out by a licensed electrician.
- Victoria operates under the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2017, with the high risk construction work, confined space and electrical provisions applying in place of the model instruments.
Frequently asked questions
What is a BESS cooling loop?
A battery energy storage system (BESS) cooling loop is the liquid cooling system that manages the temperature of a grid-scale battery system — the pipework, pumps, coolant and connections that circulate cooling fluid through the batteries. BESS cooling loop plumbing is specialised work at the intersection of plumbing and high-energy electrical systems.
What is the defining hazard of BESS cooling loop work?
The defining hazard is the proximity to the high-voltage, high-energy battery system, with the risk of electrocution and arc-flash, alongside the consequences of a coolant leak onto electrical equipment and the battery thermal-runaway hazard. The work is carried out under the operator's electrical-safety and permit systems with the electrical-proximity controls.
Why is a coolant leak onto electrical equipment dangerous?
A coolant leak onto the electrical equipment of the battery system can cause an electrical fault, fire or hazard, so coolant leaks are prevented and contained and the connections made leak-tight. Preventing coolant from leaking onto electrical equipment is a critical control because of the consequences on the high-energy electrical system.
What is battery thermal runaway?
Thermal runaway is a battery fault where the battery overheats uncontrollably, which can cause fire and release toxic and flammable gases. The thermal-runaway, fire and toxic-gas hazard is recognised and planned for with the operator's emergency arrangements, and atmospheric testing and confined space controls applied in enclosed battery enclosures.
Who carries out BESS cooling loop plumbing?
BESS cooling loop plumbing is licensed plumbing work carried out by a licensed plumber under the BESS operator's electrical-safety and permit systems, with any work on or near the energised electrical system carried out with appropriate licensed electrical and competent personnel. The plumbing is carried out with the heightened controls of the high-energy battery environment.