Managing Battery Risk in the World Around Us

Corey Hannahs, Victoria Hutchison, and Brian O'Connor, National Fire Protection AssociationEmerging Technologies, Fall 2024 Emerging Technologies

Given the current state of the world, it’s hard to imagine there was ever a time when gas lamps were used to provide illumination and Thomas Edison was still working hard to perfect the incandescent light bulb. Over the many years since that time, our electrical needs have grown from proper lighting to dependence on a multitude of electrical products to support our daily lives. Cell phones, laptops, tablets, portable chargers, even toothbrushes…the list goes on. While electricity is needed to charge these products, they all have a commonality: They are powered by batteries.

RECOGNIZING AND MITIGATING THE RISKS

Batteries, most commonly lithium-ion, have infiltrated our world, not only in the aforementioned consumer products but also in larger items like e-bikes, electric vehicles, and energy storage systems. With the inrush of batteries into the consumer market, government regulations, codes, and standards have struggled to stay ahead of the safety needs that have become more apparent. We have seen issues in battery manufacturing, such as the recent incident at South Korea-based Aricell that left 23 workers dead. We have also seen battery problems in consumer products, such as the number of e-bike deaths in New York City that continues to rise annually. It is paramount that we find a way to mitigate the battery risks that society is facing, and we must do it collectively. 

Making society safe again will take manufacturers, engineers, inspectors, first responders, consumers, and a multitude of other people. Codes and standards have always been a critical part of keeping society safe, and it is there that we are likely to find an area of common ground that will benefit all parties as they work to alleviate battery incidents throughout the world. 

We must start with how existing codes and standards requirements help with safety around batteries, but we must also look to what research is telling us about our current needs and how we address those issues. Finally, we must view the world’s battery risks holistically — from mining and manufacturing to installation and use — to apply current code requirements and fill in the gaps identified around safety needs. 

CURRENT NFPA CODES AND STANDARDS

Batteries initially receive their charge from being connected to electricity. Whether the product is small or large, it depends on an electrical system that is safe and functional to receive the proper charge. Electrical safety for these battery-operated products is achieved when:

NFPA 70

The NEC addresses the safe installation of electrical systems and products, such as energy storage systems that include batteries and electric vehicle (EV) supply equipment, such as EV chargers, which interact with the EV batteries onboard the vehicle itself. With present-day vehicle technology, many EV batteries are not only charged by a premise’s electrical system but are also capable of supplying power back to that same electrical system. The structural wiring and receptacle outlets within the premise’s electrical system can also be utilized to charge many consumer products, and the requirements in the NEC must be met to provide a safe means of charging the batteries in these products.

NFPA 70B

Although NFPA 70B specifically states that it does not provide maintenance requirements for consumer products and equipment that are used in the home, it does govern battery-related products used in commercial and industrial applications such as uninterruptable power supplies (UPS), energy storage systems (ESS), and electric vehicle power transfer systems. Aside from what may, or may not be, provided in the product manufacturer’s instructions, NFPA 70B will help a company develop an electrical maintenance program (EMP) that includes items such as frequency of maintenance and specific maintenance procedures for these products.  

NFPA 855

While there are many applications for lithium-ion batteries, one of the largest is using batteries as an ESS. This technology consists of devices capable of storing energy that can be used to supply electrical energy at a future time. Due to the large energy capacity of these storage systems, specific fire and life safety requirements to address the unique hazards can be found in NFPA 855, Standard for the Installation of Stationary Energy Storage Systems, which applies to the design, construction, installation, commissioning, operation, maintenance, and decommissioning of ESS. This includes residential installations as well as the storage of lithium metal or lithium-ion batteries. The standard has slightly different requirements based on the physical location of the ESS — indoors in a dedicated or mixed-use building or outdoors in remote locations or near exposures. Key requirements address the installation of sprinkler systems, explosion prevention/protection, equipment listings, emergency planning, fire ratings, spacing, and setback distances.  

It is also important to mention that NFPA 855 includes many helpful annexes that contain recommendations. These annexes address everything from firefighting considerations and guidance on suppression of ESS fires, to permits, an overview of various battery technologies, and even a history of code development. 

ONGOING NFPA RESEARCH

As the use of lithium-ion batteries expands across various applications — from manufacturing and storage to usage and disposal — unanswered questions about their safety continue to arise. Research is critical for developing, updating, and refining codes and standards, ensuring they are grounded in the latest scientific knowledge, technical advancements, and real-world data. 

Fire Protection Research Foundation

The Fire Protection Research Foundation (FPRF), NFPA’s independent research affiliate, has been conducting and disseminating research on lithium-ion battery applications for over a decade. This research has helped characterize emerging battery technologies; identify potential hazards and risks; evaluate the effectiveness of safety measures; address emergency response challenges; and establish best practices for usage, storage, transportation, and response.

For example, in 2016, FPRF developed protection recommendations for lithium-ion battery bulk storage through large-scale sprinkler fire tests, influencing discussions in NFPA 13, Standard for the Installation of Automatic Sprinkler Systems. In 2019, FPRF addressed suppression strategies for ESS in commercial settings, finding that a 3-ft separation between units and a 0.3-gpm/ft² sprinkler density over 2,500 ft² for 90 minutes protected lithium-iron-phosphate (LFP) ESS units effectively. These results informed action taken by NFPA 855. Additionally, NFPA 88A, Standard for Parking Structures, now requires sprinklers in parking structures, driven by FPRF report findings from 2020 and 2024 on the evolution of modern vehicle hazards. 

Independent Research

Simply put, independent research and data have the power to drive change or, at a minimum, influence and inform technical discussions. These examples illustrate the impact of research to offer interim guidance on emerging issues and provide data for technical committees to inform regulatory decisions. 

However, this process of receiving industry questions and delivering independent research and data is continual. A representative sample of other ongoing activities aimed to answer key industry questions includes:

These research activities reflect some of the most urgent needs of stakeholders and questions arising from the codes and standards process. Research from FPRF and other organizations will continue to enhance the understanding and mitigation of fire and electrical risks associated with lithium-ion batteries, contributing to the development of robust, scientifically informed safety standards and best practices.

POTENTIAL NFPA 800, BATTERY SAFETY CODE

NFPA has recognized that many regulations address the hazards associated with batteries, and it can be difficult to find all the applicable requirements for any given installation. To address this issue, NFPA has proposed a new project provisionally titled, NFPA 800, Battery Safety Code. The new code is envisioned to function similarly to a building or fire code, where it will reference and extract from existing and future standards that address elements of battery lifecycle and battery safety. This could include various NFPA codes and standards including NFPA 855 or NFPA 70, as well as external references such as product listings, installation standards, and potentially many others. This envisioned structure will be able to highlight the current regulatory gaps and help NFPA and its technical committees work towards filling those.  

The proposed scope of work includes addressing the various hazards found throughout the lifecycle of a battery to increase life safety and property protection. The code is proposed to address the various stages of a battery’s lifecycle including, but not limited to, handling and storage of raw materials, manufacturing facilities, storage of batteries in warehouse facilities, installations, decommissioning, reuse, recycling, and disposal.  

The official announcement, call for interest, and committee application for the development of this proposed standard are published at www.nfpa.org/batterysafety. You can also apply to be on the committee by visiting that link. 

CHARGING FORWARD

Despite all the challenges in the world around batteries, it should be comforting to know that many people and organizations are doing great work to try and solve the problems we are facing. While established codes and standards requirements help in many areas of battery safety, there is also a need to further develop requirements that will provide the best level of improved safety for the people of the world. Whether it is the people mining battery materials, manufacturing products, using products, disposing of products, or anyone in between, everyone has the basic human right to be safe.

Continued research around battery safety will be paramount to filling in the identified gaps in battery safety requirements. All things considered, NFPA 800, Battery Safety Code is poised to collectively pull together the work that has been done and provide a means to incorporate the additional work necessary to make the world a safer place when it comes to battery safety. It will take all of us working together to solve the battery issues we are facing. It’s a Big World. Let’s Protect it Together.® 

REFERENCES

Reuters. Accessed at https://www.reuters.com/world/asia-pacific/south-korea-begins-search-answers-after-battery-plant-fire-kills-22-2024-06-25/.

Spectrum New NY1. Accessed at https://ny1.com/nyc/all-boroughs/news/special-reports/e-bike-battery-fires.

National Fire Protection Association. NFPA 70®, National Electrical Code® (NEC®)

National Fire Protection Association.NFPA 70B, Standard for Electrical Equipment Maintenance.

For more information about how NFPA can help you to be safer around batteries, including supporting resources, please visitwww.nfpa.org/lithiumionsafety. 

Important Notice: Any opinion expressed in this column is the personal opinion of the authors and does not necessarily represent the official position of NFPA or its Technical Committees. In addition, this piece is neither intended nor should it be relied upon to provide professional consultation or services.

Corey Hannahs is a Senior Electrical Content Specialist at the National Fire Protection Association (NFPA). In his current role, he serves as an electrical subject matter expert in the development of products and services that support NFPA documents and stakeholders. Hannahs is a third-generation electrician, holding licenses as a master electrician, contractor, inspector, and plan reviewer in the state of Michigan. Having previously held roles as an installer, owner, and executive, he has also provided electrical apprenticeship instruction for over 15 years. He serves on the technical committees for UL 2272, Electrical Systems for Personal E-Mobility Devices, and UL 2849, Electrical Systems for Ebikes. Hannahs was twice appointed to the State of Michigan’s Electrical Administrative Board by former Governor Rick Snyder, and he received United States Special Congressional Recognition for founding the B.O.P. (Building Opportunities for People) Program, which teaches construction skills to homeless and underprivileged individuals.

Victoria Hutchison is a Senior Research Project Manager at the Fire Protection Research Foundation (FPRF), the research affiliate of NFPA, where she plans, manages, and facilitates research in support of the NFPA mission. Her research focuses on the hazards and protection strategies for emerging issues and technologies (e.g., battery energy storage systems, electric vehicles, and other sustainability topics) and the reliability and effectiveness of fire protection systems. At the Foundation, Hutchison also leads and manages the Detection and Sprinkler Research Planning Councils and the Energy Storage Research Consortium (ESRC). She holds an MSc in Fire Protection Engineering from Worcester Polytechnic Institute and a BSc in Fire Protection and Safety Engineering Technology from Oklahoma State University. Hutchinson also has past fire protection engineering design experience at Heritage Fire Protection, is a member of the Society of Fire Protection Engineers (SFPE), and serves as deputy editor for the SFPE Handbook for Fire Protection Engineering. 

Brian O’Connor is a Senior Engineer in the Technical Services department at the National Fire Protection Association and Past President of the New England Chapter of the Society of Fire Protection Engineers (SFPE). He is a Professional Engineer registered in the states of Texas and Massachusetts. He earned his BS in mechanical engineering from Rowan University and an MS in fire protection engineering from the University of Maryland. Prior to his current position, O’Connor was the staff liaison to NFPA 855 which focuses on topics such as batteries, water-based fire protection systems, healthcare facilities, and fire extinguishers.