As the world sees a push towards a more sustainable energy mix, batteries and battery energy storage systems (BESS) are quickly becoming a critical element in the sustainable energy infrastructure by providing the capability to even out the energy flow from wind and solar production. BakerRisk’s globally renowned expertise in flammable and explosion hazard identification, coupled with our testing and R&D capabilities, allows us to help you focus on improving the reliability and safety of battery systems, as well as explore ways to safely extend the useful life of these systems.
Why it matters
Batteries allow the ability to store excess electricity during periods of over supply to ensure availability to provide a consistent supply to the commercial grid. With the push for electrical vehicles and utilities to convert to hybrid energy solutions, battery size and energy capacity will need to increase to meet demand.
But as they lean further into battery energy storage, providers and users of battery storage systems need to consider the potential hazards associated with their manufacture and operation.
With BakerRisk’s experience in evaluating fire and blast hazards for many industries, including battery manufacturing and testing enclosures for major automotive manufacturers, our experts can help you to provide safe and reliable battery energy solutions to consumers worldwide. We can also assist companies in complying with industry standards, such as NFPA 855/68/69, UL9540/9540A and CSA TS-800:24
BakerRisk’s specialists can help to understand and manage risks for BESS projects and installations. Here are the key services we offer:
HMA is a critical and mandatory requirement for a BESS projects as per NFPA 855. It is an evaluation of potential energy storage system failure modes and the safety-related consequences attributed to the failures.
BakerRisk uses the Bowtie methodology as per NFPA 855 to facilitate and perform HMAs.
Authority Having Jurisdiction (AHJ) usually requires a completed HMA before approval of any commercial-scale BESS project
Bow-Tie Analysis is a PHA methodology combines the Fault Tree Analysis (FTA) and Event Tree Analysis (ETA) visually. The methodology is used to identify the causes of a hazardous event, its consequences, and the control measures in place. The diagram that results from this approach resembles a bow tie, with the “hazard” placed in the center. The left side of the diagram outlines the potential causes and the right-side maps out possible consequence. This methodology focuses on barriers or safeguards put in place to prevent or mitigate risks. This methodology:
As part of NFPA 855, BakerRisk performs NFPA 68 (explosion protection by deflagration venting) and NFPA 69 (explosion prevention system) analyses for clients who want to better understand the potential explosion hazards associated with their BESS designs and potential ways to mitigate these hazards and comply with AHJs requirements. BakerRisk uses a wide range of methodologies, ranging from simplified to more detailed approaches (such as computational fluid dynamics (CFD)) to assess compliance with NFPA 68 / 69. BakerRisk routinely uses the Fire Dynamics Simulator (FDS) and FLame ACeleration Simulator (FLACS) CFD codes to model dispersion, fire, and explosion hazards that could result from a thermal runaway event.
Failure Mode and Effects Analysis (FMEA) is a systematic process used to identify, analyze, and prioritize potential failures in a design or process. It is prioritizing corrective actions to prevent failures or mitigate their impact, and it is frequently used in the manufacturing, aerospace, automotive, and healthcare industries. It has a standard rating system with well-defined values that make it easier to compare results and ensure consistency which makes it highly suitable for evaluations of direct hazards and downstream impact to customers based on failure mode.
FRAs are mostly performed as an extension of HMAs. The emphasis is on the detailed analysis on the effectiveness of fire mitigation system which includes detection, suppression, ventilation etc. BakerRisk performs the fire propagation and heat flux analysis using fire modelling using FDS in certain cases that warrants such analysis.
BakerRisk will help develop a comprehensive ERP specific to the BESS facility, covering fire, explosion, and electrical safety. BakerRisk will coordinate with local emergency services to establish protocols and response actions Typically, the ERP table of contents provided in NFPA 855 will be used as the basis.
BakerRisk has conducted multiple large scale fire test at our test site in Box Canyon ( BakerRisk Box Canyon Test Facility – BCTF)
BakerRisk’s BCTF is a 2,300-acre test site that routinely supports high-hazard tests such as vapor cloud explosions (VCE), high explosive (HE) detonations, and a variety of one-off type tests (e.g., jet fire, pool fire, toxic dispersions). BCTF is located about 100 miles west of San Antonio, Texas, in Kinney County.
Two-half day course is intended to give participants an overview of the Lithium-ion battery components, primary failure modes of Battery Energy Storage Systems (BESS), and their consequences and associated mitigation techniques. Please click this link for more information. Tailored battery safety courses on NFPA 855, NFPA 68/69, Emergency Response Planning etc. are impartedas per client needs.
Services
BakerRisk has a team knowledgeable in various battery manufacturing processes and their respective hazards. Possible areas of support include:
OSHA PSM (1910.119)
Battery manufacturing facilities can fall under the OSHA Process Safety Management standard if they contain more than 10,000 lbs of electrolyte with a flashpoint below 100F (37.8C) or have a NMP recovery unit on site. BakerRisk offers Process Hazard Analysis (PHA) services using industry standard methodologies such as HAZOP, What-If, FMEA, LOPA, and others. We can work with your site to determine if it meets requirements and ensure safety standards are met with respect to industry best practices and legal compliance.
NFPA Combustible Dust (NFPA 660)
Facilities manufacturing electrodes on-site could face hazards from dust explosions if not managed correctly. BakerRisk has conducted Dust Hazard Analyses (DHA) for battery facilities in the past and will help ensure your site operates safely while complying with NFPA 660.
Design Support
Prevention is always better than mitigation. BakerRisk can come in during the design stage of battery manufacturing processes to identify safety hazards and come up with strategies for their control. Focusing on safety in the early stages of a project allows you to eliminate risk in a cost-effective manner.
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