Prevention System For Li-Ion Based Battery Energy Storage System

Energy Storage Safety & Reliability Forum 2022

JENS CONZEN | MAY 2022

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Getting Started

Agenda

+ Introduction + Explosion prevention

+ Typical BESS applications − Requirements (e.g., NFPA 69)

+ Hazard evaluation − Software tool (FDS)

− Thermal runaway & UL 9540A − System operating principle

+ Review of incidents − Source term development

− Sensitivity calculations
+ Risk
− What to pay attention to
− Probability and
consequence  Examples for detection delay impacts,
clean agent impacts, HVAC impacts,
+ General safety approach balance between flow momentum and
smooth flow regime, hot spots, hot aisle
vs. cold aisle and large buildings
 Model Validation

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Typical BESS Installations

Sources: Illustrations from GE, A123, Waldron, PV Magazine, and

Simpliphi public domains

Specialty Applications:
- Roof top
- Black start resiliency for
emergency diesel generators
- Repurposed facilities, e.g.,
factories, turbine halls

Residential

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Hazard Evaluation

Thermal Runaway

+ Thermal runaway is a process that releases large amounts of energy. Thermal runaway is strongly
associated with exothermic chemical reactions. Under a variety of scenarios (i.e., short circuit),
batteries can undergo thermal-runaway where the stored chemical energy is converted to thermal
energy.
+ Initiating events include:
− Manufacturing defects in the cells,
− Overcharging
− Overheating, and
− Mechanical abuse.
All initiating events have in common that they result in an internal short circuit of the cell, which
initiates a heat-generating reaction and may subsequently lead to thermal runaway.

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Hazard Evaluation

Thermal Runaway

+ The typical consequence is cell rupture and the release of flammable and toxic gases
+ Explosion control, ventilation, and egress are an important consideration in particular if the BESS is
adjacent to exposures

+ “Battery Gas” is usually comprised of Carbon Dioxide,

Carbon Monoxide, Hydrogen, Hydrocarbons Table 1 from Electric Power Research Institute (EPRI), 2021, Battery Energy Storage
Systems Explosion Hazards, referencing E. J. Archibald, Fire & explosion hazards due to
thermal runaway propagation in lithium-ion battery systems, PhD Thesis, 2021.

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Hazard Evaluation

UL 9540A

+ Several codes and standards, such as NFPA 855, IFC, and UL 9540,
state that the fire characteristics of a BESS that undergoes thermal
runaway should be evaluated
+ UL 9540A test data provides safety relevant information for safety
system design such as:
− Battery gas composition
− Flammability limits
− Quantity of gas generated over time
− Heat release
− Information on thermal runaway propagation timing and behavior
+ This data can be used for explosion prevention system design
+ Good input data is key for any model

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Review of Selected BESS Explosion Incidents

Possible Consequences Bodnegg, Germany, 2022

Residental BESS installed in basement.
A technical defect in the batteries caused an
explosion where the resulting pressure wave inside
+ Jet flames the house pushed out windows, doors, and lifted the
roof structure.

+ Blast waves [Link]

aus-leipzig-haus-nach-explosion-nicht-mehr-bewohnbar-
[Link]
+ Flying debris and projectiles

Surprise, AZ, USA, 2019

BESS in prefab building.
Battery thermal runaway with explosion.
[Link]
explosive-liion-energy-storage-accident

Liverpool, UK, 2020

BESS in container.
Battery thermal runaway with
explosion.
[Link]
_Event_-_UK,_Liverpool_-_15_Sep_2020

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Risk

Risk Reduction via Explosion Prevention

+ An explosion prevention system via mechanical exhaust ventilation reduces the probability of
occurrence for an explosion as well as its consequences. However, the explosion risk is not fully
eliminated:

Risk = Probability X Consequence

• Less likely to have • Controlled and automatic removal of
an explosible flammable gases protects first responders
atmosphere • Properly timed activation dilutes flammable
• Atmosphere may be concentration (less intense or no
explosible for a explosion)
shorter time frame • Toxic gases are also released in a
(depend on detection controlled way allowing for dispersion
speed) models to find consideration in emergency
response planning

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General BESS Safety Approach

General Requirements from Industry Standards

+ Monitor and Prevent

− Sensors monitor conditions
− Controls automatically keep the system within safe operation
range (e.g., charging, discharging)
+ Alert and React
− Alarm upon detection (e.g., high temperature, flammable gas)
Explosion
Prevention − Automatic shutdown and disconnect
+ Suppress Fire and Control Explosion Hazard
− Fire suppression
− Explosion control
 NFPA 68 deflagration venting, AND/OR
 NFPA 69 mechanical exhaust

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Explosion Prevention

Standard on Explosion Prevention

+ Deflagration prevention by combustible concentration reduction (Chapter 8)
+ Performance-based design option (Chapter 5)
+ For the electrical installation (Chapter 15), explosion prevention system controls
installed after November 5, 2021, shall be implemented as a Safety Instrumented
Systems!
− Certified, installed, and maintained to safety integrity level 2 (SIL-2) or better

Fire Dynamics Simulator

+ Computational fluid dynamic (CFD) code developed by the National Institute of
Standards and Technology (NIST) for the analysis of fire and dispersion of smoke and
gas
+ Provides gas concentration within the enclosure volume as function of time
+ Results can be animated and visualized in contour plots as well as graphs
+ Used for performance-based design option

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Explosion Prevention

System Operating Principle Exhaust(s)

+ Gas alarm (or other viable parameters) activates explosion

prevention system
+ Ventilation strategy: Diluting and exhausting the flammable
battery gases so that the global concentration is maintained
below 25% (by volume) of the lower flammability limit (LFL)

Gas Detector Array

Dilution air
intake(s)
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Explosion Prevention

Source Term Development

+ To support the design of an explosion

prevention system by means of reduction in
combustible concentration, the release of
combustible species (battery gas) over time into
the room or enclosure must be known
+ Review UL 9540A test data to determine
composition, temperatures, release volume,
and thermal runaway behavior (e.g., cascading
time and vent duration per cell)
− Might need to supplement with literature
data, if test report is incomplete
− Use curve fit as CFD model input

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Explosion Prevention

Sensitivities Exhaust location + The performance-based design

(high on enclosure option via CFD can be leveraged to
wall) check the explosion prevention
system performance for:
− Detection effectiveness
− HVAC mode
− Failure event location sensitivity
− Placement of exhaust(s) and
intakes(s) sensitivity
+ These transient and local details
Fresh air
would not be captured in a hand
intake
location
calculation
(low on
enclosure
wall)

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Explosion Prevention

Thoughts on Explosion Prevention for BESS Containers

+ Detection timing quickly affects explosion
prevention effectiveness
+ What is the worst-case for the exhaust system
and what is the worst case for the detection
system?
+ Explosion prevention can be challenging for
ESS with little free air volume. Options for
remedy include:
− Early detection
− Utilize a safety integrated system
− Create free air volume
+ Air-cooled BESS: Hot and cold aisle
separation might require control dampers or
two explosion prevention systems Modelling is particularly helpful to get the early timing right
or least it provides the situational awareness
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Explosion Prevention

HVAC Mode Can Affect Alarm Thresholds and Detection Time

Building ESS Example

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Explosion Prevention

General Thoughts on Explosion Prevention

+ The explosion prevention system must be properly integrated in the sequence of operations
+ There could be conflicting fire protection goals (e.g., clean agent versus exhaust)
+ The explosion prevention system must be “right-sized” for the challenge. It is a balance between
air changes and maximum possible flow velocities to provide an effective “sweep” (more is not
necessarily better)
Building ESS Example

- 2 intakes in left wall - If no override or abort in

- 6 exhaust fans on roof sequence of operations, clean
- Battery thermal runaway in agent blankets flammable gas Above
far-right corner (farthest from - Exhaust must provide enough LFL
intakes) momentum to remove clean
agent
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Explosion Prevention

Summary
Considerations Advantages

- Right-size the system - Mitigation of the explosion risk through the reduction of
- Properly integrate the system in the sequence of the probability and consequence of an event
operations. Designing and installing (or retrofitting) a - Avoidance of a catastrophic event
stand-alone explosion prevention system is only half of - Controlled release of flammable and toxic gases
the work!
- Analysis results can be used for emergency response
- Reliable and fast thermal runaway detection is key planning
- Perform various sensitivity cases to assure that the
system can detect and control the explosion hazard
under worst-case conditions Explosion control is a requirement for li-ion
- The performance criterion is less than 25% of the LFL based BESS. A mechanical exhaust
on the volume concentration. Due to the possibility of ventilation system designed and maintained
local hotspots, the explosion concern may not be fully according to NFPA 69 provides compliance
eliminated but significantly mitigated.
and risk mitigation.
- Validate the model against literature data, flow tests,
alternative models, and analytical calculations
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Thank you!
JENS CONZEN
DIPL.-ING. | EUR ING | MS | MBA
Director / Market Leader

jconzen@[Link]
M: +1 773-733-1242

[Link]