BESS Commissioning:
Make it right from the start with
Battery Analytics
Leverage field battery data to track and solve
latent issues during commissioning phase
White Paper
May 2024
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Whitepaper - BESS Safety
Introduction
COMMISSIONING PHASE, HOW CRITICAL?
In the dynamic energy storage landscape, the BESS commissioning phase
marks a pivotal juncture in an asset's lifecycle. It bridges the gap between
design and deployment, transferring responsibilities from developers to
operators. Despite its importance, crucial elements are often overlooked,
potentially compromising future operations.
The first couple of years are really key when you're running a BESS —actually, about 60% of
safety issues happen in the first two years (1), according to the EPRI, a timing that suggests
these issues are more related to suboptimal installation than to ageing. That’s why the
commissioning phase is so crucial, it's about laying down a solid foundation to catch and
mitigate potential problems before they escalate.
On top of that, the financial implications during this initial phase are significant. Consider this:
last year in Texas, the leading U.S. state for battery storage capacity, an astounding 50% of all
battery energy storage revenues were generated in just 13 days (2).
As a result, ensuring a robust & fast
commissioning process is imperative to start Commissioning is a critical phase...
generating revenue without delays and be
available on those highly lucrative days. Risk transfer
Considering the diversity of actors involved, Responsibility transfered from
tight testing schedules, and the intricate contractor to client
nature of the systems being tested, the risk of Warranty conditions to be met
suboptimal setups or critical issues going from start
unnoticed is real.
Time pressure
This reality underscores the importance of
High penalties for delays
supporting operators in achieving a seamless
Loss of revenue due to missed
start, ensuring everything operates smoothly
opportunities
from day one.
Figure 1: main stakes associated to Commissionning phase for BESS
Where do we see the most issues arising from owner/operator
during commissionning ? How can these challenges
be overcome to ensure the robustness of the BESS ?
This paper will explore the various components involved throughout the commissioning phase,
providing key answers and watchout points for any operator or owner:
Ensuring initial asset compliance through thorough checks
Verifying the comprehensiveness and accuracy of BMS data
Conducting deep analysis to uncover latent problems
(1)https://www.energy-storage.news/terra-gen-to-investigate-cause-of-valley-center-battery-storage-fire-with-incident-over/
(2)https://modoenergy.com/research/ercot-battery-energy-storage-systems-availability-revenues-
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Whitepaper - BESS Safety
Initial verification
of asset conformity
The lifecycle of any battery storage asset begins with an essential verification of initial
performance to ensure all components function optimally within specified parameters.
SATs incompleteness
The commissioning phase revolves around Site Acceptance Tests (SAT), vital during the asset
transfer phase before operational commencement to ensure compliance with OEM
specifications. Although those tests are expected to happen along clear, specific, pre-
determined guidelines, they occasionally turn out to be performed only partially, or not on the
full scope of the asset. This unnoticed incompleteness of SATs is a first critical issue: it
prevents the operator/owner from thoroughly verifying that the asset can perform as
expected, leaving him partially in the dark before day one of operation.
To remove this blindfold, operators must be well-equipped to ensure proper execution of the
tests; this means leveraging external and unbiaised tools that can analyze field data to
accurately assess the asset's condition. This cross-party validation provided by battery
analytics includes:
Verify that tests are performed according to OEM integrator requirements
Make sure the tests are performed on the complete scope of the asset
Tracking key metrics against requirements
To compare tests results with requirements, a detailed analysis of the full charge/discharge
cycles is conducted. Verifying that the C-rate and temperatures align with the
manufacturer’s guidelines and the intended use outlined in the warranty conditions
ensures operations remain fully supported by warranty. This step also opens the door for key
discussions with the integrator, equipment manufacturer, and owner on power
management strategies for optimal performance.
The figure below illustrates how battery analytics can assist operators with various checks
and, in this case, how they helped identify out-of-warranty usage.
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Identification of out-of-warranty C-Rate on specific racks
What’s the issue?
Several battery racks
operate very close to
the C-rate limit, or even
beyond it, especially
during discharge
What’s at stake? How to solve it?
A deviation from the initially With the integrator still on-site,
intended usage profile can a recalibration can be
compromise warranty performed to bring the usage
management right from the start profile back within the specified
of the asset’s operation conditions
Figure 1: C-Rate dispersion analysis vs warranty, for charge and discharge phases
By ensuring adherence to these verification stages, the operator can trust in the asset's
capability to operate as intended, aligning with the specified conditions set by the OEM and
guaranteeing warranty coverage.
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Assessing BMS data
collection accuracy
While initial tests may confirm that initial performance meets specifications, this alone does
not guarantee that the system is in perfect working order or will remain so in the future.
The owner/operator fundamentally needs to be given operational tools of monitoring that are
functional from day one. This involves verifying the data provided by the BMS (Battery
Management System).
The BMS is a crucial, intelligent component that not only manages the battery’s charge and
discharge cycles but also continuously monitors vital parameters such as temperature,
current, and voltage. Calibration errors or sensor faults within the BMS can result in inaccurate
readings, which, if not promptly identified and corrected, could precipitate system failures or
create safety hazards prematurely.
Concretely to ensure the BMS is effectively monitoring and reporting data, several checks
are necessary:
Controller signal verification: Examine what data signals are collected to ensure all vital metrics can
be computed. Missing or inconsistent data may indicate issues with data collection configurations or
faulty monitoring components.
Physical measurement consistency checks: Ensure that the temperature, voltage, and current
readings from the BMS match the battery's actual operating conditions. Any discrepancy may point
to sensor inaccuracies or configuration errors in the system.
Detection of defective module via abnormal BMS behavior
What’s the issue?
Unexpected and unexplained Voltage and SOC
drop with no current applied, followed by
spontaneous recovery – a phenomenon that
defies physics!
What’s at stake?
This suggests a BMS malfunction, leading to a
risk of false-positive alarms
How to solve it?
Investigation with the battery provider to resolve
the software configuration issue
Figure 2: Detecting abnormal behavior using Voltage, SoC and Current field data
These steps are crucial to ensure the precision and reliability of the BMS data, which is
essential for making informed decisions about performance and safety down the line.
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Delving deeper for
operational stability
Pinpointing latent defects to prevent operating drifts
Remember that 60% of incidents occur within the first two years of operation (EPRI), so
going beyond initial test verification and BMS settings checks should not merely be considered
an option. A proactive scrutiny is necessary to uncover any latent defects that might escalate
into significant safety hazards later on.
Safety and temperature alerts
The first step is identifying metric excursions, as deviations
Learn more on
beyond acceptable limits can not only void warranties but also
BESS safety
signal deeper underlying issues such as potential safety risks,
hardware malfunctions, or performance limitations.
Temperature is one of the critical metrics. Monitoring sudden spikes is imperative. Yet, more
critical than mere identification is the ability to pinpoint their source. Understanding the root
cause of an issue is paramount to resolving it effectively. A proactive approach enables
preemptive action long before the issue manifests.
Root cause identification relies on an in-depth investigation, involving a comprehensive
analysis of various clues extracted from battery data. For example, when temperature outliers
are detected, it is important to inspect other drifting behaviors such as HVAC operating
status, resistance levels or sensor readings to identify the root causes. Only such detailed
analysis of these behaviors can help operators adeptly prioritize concerns.
Detection of a safety problem and pinpointing its root cause
What’s the issue?
Abnormal rise in the 'Max
Temperature' metric up to 55°C
when current is applied to this
specific rack (fig 3.1), correlated with
significant resistance drift (fig 3.2)
Temperature max Temperature avg Battery current
Figure 3.1: Individual rack DC resistance evolution
What’s at stake?
Symptomatic of a defective electrical
DC resistance distribution
connector that can lead to thermal runaway
How to solve it?
Temporary closure of the rack to prevent safety
Resistance (Ohm) problems while the faulty module is replaced
Figure 3.2: Abnormal temperature increase when battery is cycling
Figure 3: Detection of safety issue based on individual rack DC resistance evolution and abnormal temperature increase
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Whitepaper - BESS Safety
Identifying these latent defects early can prevent operational drifts and ensure the system
operates within its optimal safety and efficiency standards throughout its operational life. This
level of analysis not only safeguards the asset but also optimizes its performance and
longevity.
Cell imbalance detection
More insidious, cell imbalances are harder to detect but, if left Learn more on
cell imbalance
unchecked, can escalate into serious safety concerns. Deep
analysis of cell behavior is then critical for unlocking the full
potential of your energy storage asset.
Cell imbalance is a complex issue that manifests
at various levels—whether within racks or
modules—and arises from multiple causes, which
complicates the resolution process. Even when
brand new, there may be cell imbalances right
from the start of the asset's deployment,
originating directly from the factory. Detecting
these imbalances is crucial, and the BMS, capable
of monitoring each cell's voltage, can help
identify certain types of imbalances. However, for
LFP batteries—widely used in the industry— it
may struggle. It is therefore essential for the
operator to be able to detect any type of cell
imbalance, given its significant impact on the
asset's efficiency.
Learn more on
LFP vs NMC Figure 4. Schematic illustration of battery cell imbalance
Detection of cell imbalance reducing battery efficiency
What’s the issue?
Recurring cell imbalance alerts attributed to
SOC dispersion; deeper investigation does not
flag any structural issue at a more granular
level
What’s at stake?
No safety risk detected but a reduction in
useful capacity and therefore in the asset's
revenue potential
How to solve it?
Rebalancing procedure to increase SOH and
thus recover useful capacity
Figure 5: Detection of cell imbalance linked to escalating SOC deviation and drop in SOH
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Whitepaper - BESS Safety
Conclusion
The commissioning phase isn't just a procedural necessity—it’s critical for the health and
profitability of BESS. Early detection and resolution of issues can significantly reduce future
costs. Ensuring everything is up to spec from day one also maximizes the benefits of warranty
coverage, giving an extra layer of financial and operational peace of mind.
To truly optimize this phase, it’s crucial to leverage solutions that provide real-time
insights with a strong focus on the battery. Integrating deep electrochemical & data
expertise, battery analytics offers a comprehensive understanding of asset
performance, identifying even the most subtle or hidden issues. Discover PowerUp's
unique approach to the commissioning phase below.
PowerUp’s unique approach of commissioning audit
Deep-tech capabilities brought through expert services
Advanced analytics PowerUp expertise
Ability to ingest high volumes of data Insights digests and reports produced by our
team based on analytics output
Proprietary and automated computation
capabilities Clear recommendation provided by our team of
battery experts and electrochemistry PhDs
Granular output: drill-down capabilities to zoom
in on weak spots and investigate root cause Additional spot-on or ad-hoc analysis available
on-demand
Our complementary approach combines the capabilities of our Battery Insight®
platform with expert support to deliver a comprehensive range of analyses, from asset to
module. This enables rapid problem resolution, backed by data analytics, to pinpoint
root causes and support warranty management.
Improve your BESS commissioning
to save time and money
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Whitepaper - BESS Safety
About PowerUp
PowerUp develops advanced battery analytics solutions to ensure a safe, reliable, and
maximized use of lithium-ion batteries in operations used in utility-scale BESS. By
leveraging physics-based battery data collected by the BMS and processed through
patented algorithms, the monitoring solution provides proprietary indicators and gradual
alerting system on the batteries actual use, state of safety, performance and lifetime.
With +15 years of R&D in electrochemistry, the company combines its enduring battery
expertise with advanced data processing capabilities; its solutions help BESS owners and
operators unlock the full potential of their batteries while reducing safety risks and
minimizing cost of operations.
PowerUp’s Battery Insight® cloud-based platform is the go-to solution for players willing
to gain deeper understanding of their batteries, ensure long-lasting performance and
protect their asset against accelerated degradation.
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White Paper
May 2024
@PowerUp 2024 - All right reserved www.powerup-technology.com
