ENE/General/TBT-ENE-027

Battery Energy Storage System (BESS) Safety

Energy & RenewablesGeneralBattery Energy Storage System (BESS) Safety

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Toolbox Talk

Battery Energy Storage System (BESS) Safety

TBT-ENE-027

Battery energy storage systems are increasingly being installed alongside solar farms, wind turbines, and electrical substations across the UK. These systems store large amounts of electrical energy in lithium-ion or similar battery cells. Thermal runaway, toxic gas release, and high-voltage DC exposure are the primary risks during construction and commissioning. This talk covers the safety controls for BESS installation on UK sites.

Key Hazards
Thermal runaway causing fire and toxic gas release from battery cells
High-voltage DC shock from exposed battery connections during installation
Toxic fume inhalation from hydrogen fluoride released during battery fire
Explosion from flammable gas accumulation inside battery enclosures
Control Measures
  • Ensure all electrical work on BESS systems is carried out by qualified, authorised electricians.
  • Isolate and verify dead all DC circuits before making or breaking any battery connections.
  • Use insulated tools rated for the system DC voltage during all installation and maintenance work.
  • Install gas detection and fire suppression systems as specified in the BESS design before commissioning.
  • Maintain exclusion zones around battery containers during energisation and commissioning stages.
  • Store battery modules in climate-controlled conditions before installation as specified by the manufacturer.
  • Brief all operatives on the thermal runaway emergency procedure and evacuation routes.
  • Ensure adequate ventilation in battery enclosures to prevent flammable gas accumulation.
  • Coordinate commissioning activities with the distribution network operator and system integrator.
Emergency / Rescue

If thermal runaway is suspected, evacuate immediately upwind. Call 999 stating battery fire with toxic gas risk. Do not attempt to fight a lithium-ion battery fire with water. Maintain a 50-metre exclusion zone. Hydrogen fluoride gas may be present.

Remember
  • Isolate and verify dead all DC circuits before making or breaking battery connections
  • Use insulated tools rated for the system voltage during all electrical work on BESS
  • Know the thermal runaway emergency procedure and evacuation routes before work begins
  • Gas detection and fire suppression must be installed before the system is energised
  • Maintain exclusion zones around battery containers during energisation and commissioning
Applicable Legislation: Electricity at Work Regulations 1989 · DSEAR 2002 · Regulatory Reform (Fire Safety) Order 2005 · BS EN 62619 (Secondary Lithium Cells Safety)
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