Microgrid Safety: A Critical Element of Sustainable Energy

Microgrids have rapidly emerged as the preferred strategy for maintaining resilience and cost efficiency in industrial settings. Microgrid technology helps leaders in manufacturing and production industries take control of how their energy is generated, distributed, consumed, and managed, providing unparalleled resilience, flexibility, and sustainability. These benefits yield a significant competitive advantage in today's challenging industrial landscape.

The rise of Industry 4.0 — the current trend of automation and data exchange in manufacturing technologies — has underscored the necessity for reliable and continuous power supply. It also intensified the need for microgrid safety protocols and standards as grid use grows in popularity and complexity.

Microgrids must be designed and operated under stringent safety protocols to prevent accidents and sustain consistent performance, even under adverse conditions. The complexity of modern manufacturing processes necessitates a grid that is resilient to sudden disruptions and capable of providing steady energy flow.

Reliability is foundational to safe and stable operations. Microgrids must offer power continuity to avoid impacts on production cycles or compromised data integrity. Safely achieving these goals requires interoperable equipment and tech-enabled power management to anticipate potential issues, mitigate anomalies and maintain smooth operations.

The industrial microgrid landscape

Navigating the energy landscape in industrial sectors presents a unique set of challenges and opportunities.

Industrial users looking for efficient, resilient, and cost-effective power solutions face several obstacles: 

• Growing consumption – As industrial needs and consumer demand grow, companies’ power consumption must increase to meet the demand. This requires microgrids to be modular and scalable to keep up over time.
• Increased energy volatility – Increased power consumption and threats from environmental and climate conditions cause supply chain issues in energy production and delivery. Microgrids mitigate these impacts through localized delivery and flexible production sources, including solar and wind.
• Compliance changes – Although microgrid safety standards are still under development companies must be prepared to meet local municipal requirements; manufacturer and installer standards; operational minimum standards; and environmental, safety and governance (ESG) standards. This multi-front compliance landscape requires careful microgrid design and implementation to facilitate approvals and continued operation.

An inherent safety challenge of microgrids is integrating these technologies within existing infrastructures.

The role of microgrids in business resilience

Microgrids can be instrumental in promoting business resilience. By providing a stable power supply, microgrids help companies avoid downtime, maintain productivity, and prevent resource wastage.

Microgrids are also central to sustainable business practices. By incorporating renewable energy sources into power production, multi-source grids reduce dependence on fossil fuels and offer protection against unpredictable energy costs or supply interruptions. Advanced power management systems help reduce waste and safety incidents.

The imperative of safety in industrial microgrids

Complying with regulations builds public trust and enables safe integration of energy sources. Prioritizing safety supports operational continuity, safeguards humans (and other living creatures) and equipment and promotes system stability.

Fire hazards

Microgrids often employ various energy sources, including fuel cells and generators. If these systems are not properly maintained or monitored, they can overheat or malfunction, which may lead to fires. This poses a significant risk to personnel safety and can cause extensive damage to equipment and infrastructure.

Electrical injuries

The integration of multiple energy sources and complex electrical systems presents risks of electrical shock. Such incidents could result in severe injury or death for personnel.

Power outages

Safety lapses may lead to system failures and cause unforeseen power outages. Unexpected downtime may result in financial losses and undermine the reliability of the microgrid.

Grid instability 

Neglecting safety compromises the stability of the overall grid system. Fluctuations or disruptions in power supply can impact connected networks, affecting wider communities beyond the industrial site.

Environmental damage

Leaks or spills from fuel-based energy sources could lead to environmental contamination. This could result in potential legal penalties, cleanup costs, reputational damage, and contravention of ESG standards.

Enhancing reliability through safety measures

Improving microgrid safety offers the added benefit of boosting reliability. Microgrids, by design, are complex systems that present safety risks if not well managed. However, well-managed energy systems are often inherently reliable and cost-efficient.

Safety measures help facilitate the smooth operation of the individual components in the microgrid system. Safety programs establish safeguards such as regular maintenance checks, advanced exception alerts and rapid troubleshooting to prevent incidents or outages. This level of vigilance helps prevent issues that can reduce downtime or continuity.

Safety protocols help preserve the integrity of the grid, defining how different power sources are to be integrated to avoid overload situations and disruptions. Effectively managing these factors keeps the power supply steady and grid performance stable.

A strong safety protocol helps operators respond effectively during safety incidents. Documentation guides operators through potential scenarios such as fluctuations in demand and supply disruptions due to weather conditions. A well-implemented safety plan provides clear procedures under such circumstances, preventing hasty decision making that could compromise security and reliability.

Microgrid safety measures offer peace of mind across many facets of operation, making safety a top priority for the stakeholders involved in microgrid design, installation, and functionality.

Risk mitigation strategies in microgrid design and operation

In energy management, mitigation strategies may create hundreds of thousands of dollars in cost avoidance and risk mitigation.

Every microgrid operator must establish a robust risk mitigation program. This includes conducting thorough research into relevant standards, understanding, and adhering to local regulations, creating comprehensive documentation, and maintaining effective communication.

The following elements of microgrid safety planning help optimize outcomes:

Maintenance and inspections – Conducting periodic checks and maintenance of the microgrid can detect potential faults early. This preventive measure reduces the risk of unexpected system failure, enabling continuous power supply and operational stability.

Load management procedures – These protocols balance energy supply and demand. They help prevent overloads by adjusting energy production or consumption as needed. The result is a resilient system that can withstand sudden changes in demand without disruptions.

Emergency response plans – These outline steps to take during a crisis, such as adverse weather or technical malfunctions. They allow operators to act swiftly and decisively, minimizing downtime and maintaining grid reliability. Emergency response plans should include hierarchies for decision making, reporting and coordination with authorities having jurisdiction (AHJs) to provide clear actions in emergency scenarios.

Cybersecurity policies – Microgrids are increasingly digitized and connected, raising concerns about cyber threats. Robust cybersecurity measures help protect the grid from attacks and preserve its operational integrity and reliability.

Personnel training – Regular training helps staff members gain proficiency in operating procedures, safety protocols and emergency responses. A highly skilled workforce is crucial for preventing mishaps and maintaining smooth operation of the microgrid.

The future of industrial microgrids: Safety and beyond

As energy-intensive industries grow and more companies seek out energy management and independence, the need for microgrids will expand. With this comes the need for stringent safety certifications, testing and education so that power remains safe, accessible, and economical.

Energy management industry leaders need strong partnerships to keep microgrid power safe and achievable. UL Solutions applies expertise in safety science, testing and certification through its participation in the development of standards and code requirements.

Compliance and standards for safety in microgrids

Technical committees are currently working on outlining the requirements for distributed energy resource systems, single-site energy systems and microgrid controls to address the following:

• Power quality during islanded or stand-alone operation.
• Interoperability between energy sources.
• Synchronization of energy sources with the utility or other microgrids.
• Abnormal operation, system faults and foreseeable operator misuse.
• Cybersecurity threats.

UL 3001, Distributed Energy Generation and Storage Systems

This document is applicable to large commercial microgrids with multiple buildings, multiple utility connections or more than one energy source.

Other guidance for industrial microgrid applications includes UL 1741 Supplement SA (the Standard for Inverters, Converters, Controllers and Interconnection System Equipment for Use With Distributed Energy Resources, Supplement A), which addresses inverter performance during abnormal grid conditions.

During the design and installation process, installers, designers, and manufacturers of microgrid components must also consider other relevant codes and standards, guides, and safety concerns, such as the following (this list is by no means exhaustive):

NFPA codes and standards

The National Fire Protection Association (NFPA) develops codes and standards that help enable safe electrical installation, and inspection to help protect people and property from potential hazards associated with electricity. NFPA 70, also known as the National Electrical Code^® (NEC), encompasses the main standards for installation and inspection in the U.S. and guards against electricity-related incidents and hazards. The NEC provides guidelines for all facets of electrical installation, including residential, commercial, and industrial settings. NEC also holds legal status when states and municipalities adopt it into law.​​

NFPA 855 is a standard for installing stationary energy storage systems, including those used in microgrids. It encompasses safety regulations regarding placement, ventilation, fire detection, and suppression mechanisms.

The NFPA regularly updates these guidelines to reflect technological advances and industry best practices.

IEEE standards

The Institute of Electrical and Electronics Engineers (IEEE) sets international standards across various technologies, including microgrids. For instance, the IEEE 1547 series outlines the technical specifications for connecting distributed resources to electric power systems. This standard plays an essential role in integrating microgrids into larger grid systems.

IEEE 2030 addresses standards for smart grid interoperability. It provides a knowledge framework for architectural and operational considerations when designing and managing smart grids, including microgrids.

Residential and industrial microgrid safety considerations

Residential and industrial microgrids require robust strategies to mitigate the risk of safety hazards. However, the differences between residential and industrial systems calls for distinct approaches.

Residential grid considerations

In residential microgrids, risk mitigation primarily focuses on maximizing energy security and reliability for homeowners. Prevention of power outages are a key concern, with strategies often involving redundancy measures such as backup power sources or energy storage systems. Resident education about energy use and emergency procedures forms an essential part of the strategy.

Some microgrid suppliers offer integrated management solutions for solar arrays, backup power storage and grid integration. This allows the homeowner to view current production and usage stats, balance usage in different power scenarios, and take advantage of monitoring in a simple and straightforward presentation.

Industrial grid considerations

Industrial microgrids focus on providing continuous operation and eliminating risk. These grids must address power reliability and safety risks related to the specific industrial processes they support. Cybersecurity becomes a higher priority in industrial settings due to heightened connectivity (and the potential impacts of an attack). Robust firewalls, extensive intrusion detection systems and regular security audits help keep industrial systems safe.

Risk mitigation also involves comprehensive personnel training for stakeholders who manage sophisticated equipment or respond to industry-specific emergencies.

While both microgrid use cases prioritize reliability and safety, residential strategies lean toward managing localized risks, while industrial ones need to handle extensive systemic threats with potential broad-scale consequences.

Cybersecurity regulations for microgrid applications

These regulatory and certification bodies cover cybersecurity standards for microgrids:

National Institute of Standards and Technology (NIST) develops guidelines to enable these systems’ security. It specifically provides a cybersecurity framework catering to various sectors, including energy.

North American Electric Reliability Corporation (NERC) establishes strict critical infrastructure protection standards that address security risks in microgrids.

The International Electrotechnical Commission (IEC) issues global standards for electric technologies. IEC 62443 is particularly relevant, as it focuses on industrial automation and control system (IACS) security, which includes microgrid systems.

The American National Standards Institute (ANSI) plays a vital role in maintaining electrical microgrids by promoting the development and use of standards. ANSI helps enable the safety, reliability, and efficiency of these systems through its accreditation of standards developers.

The International Society of Automation (ISA) developed ISA-99 (ISA/IEC 62443) standards and technical reports to address and mitigate security vulnerabilities in IACS, including microgrids. This helps strengthen the resilience of critical infrastructures against cyber threats.

UL 2941, the Outline of Investigation for Cybersecurity of Distributed Energy and Inverter-Based Resources, provides testable requirements for photovoltaic inverters, electric vehicle (EV) chargers, wind turbines, fuel cells and other resources that are essential to advancing grid operations.

These cybersecurity standards and outlines of investigation apply to industrial automation and control systems used in microgrids. They guide installers and operators to protect these systems from cyber threats that could disrupt operations or cause harm.