EPRI Battery Energy Storage Systems (BESS) Failure Incident Database

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Manufacturing as a root cause has the fewest failures attributed to it. This is most likely due to the difficulty in de- finitively identifying a manufacturing defect as a root cause with the loss of physical evidence after a fire or explosion. Earlier failures from 2018-2020 in particular may have involved cell or module manufacturing defects as a contrib- uting factor. Several product recalls from major EV manu- facturers during those years cited manufacturing issues by battery OEMs.12,13 Some residential ESS products were also recalled during the same timeframe.14 It is important to note that recalls do not definitively point to manufacturing issues, but indicate the probable failure cause. In recent years, more robust product standards such as Underwriters Laboratory (UL) 1973 (Standard for Batteries for Use in Light
Electrical Rail Applications and Stationary Applications) and UL 1642 (Standard for Lithium Batteries) have improved the quality of manufactured batteries. Product certifications include quarterly and annual audits of factories to review quality control procedures, part inspection standards, and more. A recent report from Clean Energy Associates (CEA) summarizes findings from BESS factory quality audits. Of the identified issues in cell and module manufacturing, the majority were classified as minor issues, meaning they were not expected to impact safety in the short or long term.15
Failed Element
The distribution of failure sources across BESS elements (i.e. components) provides an insightful view of the vulner- abilities within the system.
Figure 6. Breakdown of BESS Failures by Failed Element
12 Gitlin, J. Multiple recalls spark Fed investigation of LG’s electric car
batteries. Ars Technica, 2022. https://arstechnica.com/cars/2022/04/
multiple-recalls-spark-fed-investigation-of-lgs-electric-car-batteries/.
13 De Chant, T. GM recalls every Chevy Bolt ever made, blames LG
for faulty batteries. Ars Technica, 2021. https://arstechnica.com/ cars/2021/08/gm-recalls-every-chevy-bolt-ever-made-blames-lg-for- faulty-batteries/.
14 United States Consumer Product Safety Commission. LG Energy Solution Michigan Recalls Home Energy Storage Batteries Due to Fire Hazard.
15
BESS Quality Report. February 2024. Clean Energy Associates Insights.
9 | EPRI White Paper 15256168
May 2024