BESS Energy Risk: Expert Videos on Safety and Prevention

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Red umbrella logo: Travelers

Text: BESS Failures: What the Data Shows Understanding BESS Failures
Text: Lakshmi Srinivasan, Principal Team Lead, Energy Storage, EPRI

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LAKSHMI SRINIVASAN: Battery energy storage systems can and have been operated safely. While failures are rare, they can be costly. EPRI maintains the most comprehensive public database of safety-related failures in utility scale and commercial lithium-ion BESS. It tracks global incidents that have resulted in large-scale fire or explosion.

Each record includes system size, age, chemistry, application and operational status when available. The data is based on public sources like news reports and investigation summaries. So while extensive, the database may miss incidents with limited media coverage. Still, it provides a valuable foundation for understanding trends and improving safety.

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Text: Tracking Progress in Safety.
 
A bar graph with years 2018 through 2024 on the x-axis and Cumulative Deployment (GMh) on the y-axis shows a line labeled Failure Incidents per Deployed GWh that decreases from 300 in 2018 to about 40 in 2020, increases slightly before trailing off in decline until 2024. The values of the bars are the Failure Incidents: 16 in 2018, 14 in 2019, 4 in 2020, 11 in 2021, 13 in 2022, 15 in 2023, and 8 in 2024. An increasing slope is labeled Cumulative Deployment (GWh) squared. Text: Sources: (1) EPRI Failure Incident Database, (2) Wood Mackenzie, Global Energy Storage Outlook Data as of 12/31/24.

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EULA BILLAUT: Since 2018, global BESS deployment has skyrocketed, from 10 gigawatt-hours to over 300 gigawatt-hours. Yet the number of failure incidents per year has remained steady. This means the failure rate has dropped by 98%, a dramatic improvement driven by product evolutions and lessons learned from earlier incidents.

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Text: Eula Billaut, Project Engineer, Energy Storage, EPRI Source: EPRI

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For example, fires in 2018 and 2019 were often linked to improper operation limits. Since then, better controls and clearer SOC and voltage thresholds have reduced such failures. Industry- wide standards have also evolved rapidly, with new UL certifications, fire codes and electrical regulations targeting large battery systems.

The battery industry continues to advance safety practices, applying research and real-world experience to reduce risks and enhance system reliability.

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Text: What Makes BESS Systems Safer.

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LAKSHMI SRINIVASAN: BESS safety requires a layered approach, from cell chemistry and module design to system level sensors, fire protection and explosion prevention. Proper integration, monitoring and maintenance are key, along with spacing and site layout.
 
Beyond the site, training, emergency planning and community engagement help manage risk. Safety must be built into every stage of the BESS life cycle, to reduce both the likelihood and impact of an incident.

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A cluster of rectangular columns in a pine forest with arrows around it point clockwise. Text clockwise around the circle from top right: Planning, Battery Explosion Hazard Calculator, Proactive First Responder Engagement, Community Engagement, Community-Based Siting / Permitting. Procurement & Design Safety Specifications, Codes and Standards, Burn Testing Results. Deployment & Integration, Emergency Response Plan Guidelines, Air Emissions Plume and Suppression Water Runoff Modeling. Operations & Maintenance, Utility Leading Practices (PPL, EPRI and U.Ky) Safety Retrofit Guide. Decommission & Recycle, Carnegie Road Energy Storage System Failure Lessons Learned, Damaged, Defective and Recalled Module Decommissioning. Text at bottom: Copyright 2025 Electric Power Research Institute, Inc. All rights reserved.

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Red umbrella logo: Travelers. Text: Talk to your independent agent or visit travelers dot com slash Energy, Copyright 2026 The Travelers Indemnity Company. All rights reserved. Travelers and The Travelers Umbrella are registered trademarks of The Travelers Indemnity Company in the U.S. and other countries. This material does not amend, or otherwise affect, the provisions or coverages of any insurance policy or bond issued by Travelers. It is not a representation that coverage does or does not exist for any particular claim or loss under any such policy or bond. Coverage depends on the facts and circumstances involved in the claim or loss, all applicable policy or bond provisions, and any applicable law. Availability of coverage referenced in this document can depend on underwriting qualifications and state regulations.

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Text: Travelers. BESS Construction Risks: Transportation and Preparation. Transportation Risks. Rod Reid, Risk Control Technical Director, Travelers.
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ROD REID: When it comes to the safety of battery energy storage systems, risk management starts well before the unit is energized. It begins with transportation.

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A bullet point list appears one point at a time. Text: Carrier vetting is critical. Use FMCSA tools.

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BESS units are high-value, high-risk cargo, so carrier vetting is critical. Check the carrier's roadside inspection performance history on the Federal Motor Carrier Safety Administration's website SAFER or SMS. Vehicle maintenance issues, trends in cargo securement or other concerns may assist in carrier selection.

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Planning Before Delivery. A bullet point list appears one point at a time. Text: Pre-inspect access routes. Check for visible damage. Site should be clear, level and elevated.

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Before delivery, plan ahead. Review the access route, especially for remote sites, and confirm the roads are level with gradual incline and can handle heavy loads. When the unit arrives, inspect it thoroughly for any visible impairment, such as dents or water damage. Where the BESS unit will be placed should be prepped, so it is clear, level and elevated to avoid drainage issues. It should be placed away from traffic zones and other equipment and have barriers to prevent accidental strikes.

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Unloading Safely and Strategically.

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Unloading is another risk point. Whether using a crane or lull, make sure rigging is in good condition. It should be free from tears or abrasions and rated for the weight of the load. And make sure a pick plan is in place. If using a crane, best practices include use of certified operator, cribbing to stabilize outriggers and proof rolling, where applicable, to mitigate rollover potential. The goal isn't just to unload, it's to do so safely.

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Prepping the Unit – Conditions for a Safe Start. A bullet point list appears one point at a time. Text: Aim for on-time delivery. Verify HVAC readiness. Follow OEM guidelines. Arch flash safety protocols. Emergency response plan.

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Before the unit is ready to go live, store it properly in a temperature-controlled, protected environment. Ideally, on-time delivery for immediate installation is a best practice to avoid temporary storage concerns. When placing the unit, adhere to spacing requirements, especially near other units or buildings. It is important to prevent water or dust intrusion whenever the cabinet is accessed and during commissioning. Always follow OEM guidelines and work with certified contractors who are trained in arc flash, electro shock and fire risks.

Check that the HVAC system is functioning, and most important, have an emergency response plan in place before energizing the system. Finally, run through your startup checklist. At this stage, even small oversights can cause big problems.
 
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BESS Safety Begins Before Day One.

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Every phase before activation is an opportunity to reduce risk. Plan ahead, prequalify your partners and prepare the ground, both literally and figuratively, for a safe and successful launch.

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Travelers. Talk to your independent agent or visit travelers dot com slash Energy. Copyright 2026 The Travelers Indemnity Company. All rights reserved. Travelers and The Travelers Umbrella are registered trademarks of The Travelers Indemnity Company in the U.S. and other countries. This material does not amend, or otherwise affect, the provisions or coverages of any insurance policy or bond issued by Travelers. It is not a representation that coverage does or does not exist for any particular claim or loss under any such policy or bond. Coverage depends on the facts and circumstances involved in the claim or loss, all applicable policy or bond provisions, and any applicable law. Availability of coverage referenced in this document can depend on underwriting qualifications and state regulations.

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Text: Travelers. BESS Construction Risks: Testing and Commissioning. Commissioning a BESS Unit.

Rod Reid, Risk Control Technical Director, Travelers.

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ROD REID: Testing and commissioning of BESS is the final critical step before going live and one of the most important for long-term safety and performance. This is when the system is verified to safely integrate with solar or wind generation and to connect to the grid. It starts with a clear integration plan, ensuring compatibility between inverters, the BESS and site infrastructure.
Proper sequencing and energization are essential. That might mean load testing or step-by-step energizing, often with a manufacturer's representative on-site.

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What to Check Before Going Live.

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Before startup, all safety systems must be online and functioning. (DESCRIPTION)
 
A bullet point list appears one point at a time. Text: HVAC systems. Fire suppression. Temperature monitoring.

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This includes HVAC systems to maintain safe battery temperature, fire suppression, which must be tested and charged, and temperature monitoring to alert early if problems arise. All this ties to the SCADA system, the central brain of the BESS, and tracks performance data, controls HVAC and other subsystems, and flags critical conditions like humidity, overheating or any faults. If SCADA isn't live and communicating clearly, the BESS shouldn't be either.

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Testing, Performance and Contingency Plans.

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Next, walk through your startup checklist.

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A bullet point list appears one point at a time. Text: Start-Up Checklist. BESS unit tied to grid. SCADA data and alarms. Key benchmarks met.

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Confirm that each BESS unit is properly tied to the grid. Ensure that SCADA data and alarms are being received and reviewed. And also verify that the system meets key benchmarks like voltage, capacity and discharge performance. And always have a contingency plan. If the unit doesn't pass commissioning, you'll want pre-defined next steps, especially given lead times for specific parts and technician visits.

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System Live, Risks Minimized. (SPEECH)
 
Commissioning isn't just the final step, it's the point where every prior investment pays off. Get the sequencing right, verify the systems and make sure your BESS is ready to go live, safely and intelligently.

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Travelers. Talk to your independent agent or visit travelers dot com slash Energy. Copyright 2026 The Travelers Indemnity Company. All rights reserved. Travelers and The Travelers Umbrella are registered trademarks of The Travelers Indemnity Company in the U.S. and other countries. This material does not amend, or otherwise affect, the provisions or coverages of any insurance policy or bond issued by Travelers. It is not a representation that coverage does or does not exist for any particular claim or loss under any such policy or bond. Coverage depends on the facts and circumstances involved in the claim or loss, all applicable policy or bond provisions, and any applicable law. Availability of coverage referenced in this document can depend on underwriting qualifications and state regulations.

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Text: Travelers. BESS Operational Risks: Thermal Runaway. The #1 Risk for Lithium-Ion Batteries.

A man sits in front of a gray background. Text: Marek Strojvus, Risk Control Forensic Specialist, Travelers.

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MAREK STROJVUS: As with any technology, battery energy storage systems offer many advantages but also come with potential hazards. These hazards not only impact the efficiency of the operation, but they also pose significant safety risks.

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Thermal runaway: The most prevalent BESS risk.

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The most prevalent risk with the BESS is thermal runaway, a phenomenon in which the lithium- ion cell enters an uncontrollable self-heating state. This condition occurs when the heat internally generated exceeds the ability of the cell dissipation capability.

Once a thermal runaway event is triggered, it can lead to the emission of flammable and toxic gases, causing a chain reaction within adjacent cells, which is why we call a thermal runaway, and the event must be monitored and controlled until all fuels are exhausted.
 
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Source: Sanderson, Cosmo. “Green energy godsends or bombs waiting to go off? Giant lithium- ion batteries draw fire-risk scrutiny." Recharge news dot com. February 2024.

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As an example, it took four days, 30 fire engines and 150 firefighters to bring a fire under control at a Tesla Megapack energy storage facility in Australia back in 2021.

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The Consequences of Thermal Runaway. A bullet point list appears one point at a time. Text: Smoke, fire explosion. Property damage, including equipment. Personnel safety hazards.
Possible environmental impact.

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There are several consequences of the thermal runaway, including smoke, fire, explosion, property damage, including the equipment, personal safety hazards and possible environmental impact, such as the release of airborne particulates during fire and polluted runoff from firefighting water.

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The Causes of Thermal Runaway.

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Thermal runaway can result from both internal cell failures and external stressors.

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A bullet point list appears one point at a time. Text: Internal failures. External stressors.

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Internal failures may include issues like manufacturing defects or separator breakdown that compromise the integrity of the cell. External causes include mechanical abuse or damage, extreme temperatures like too hot or too cold, and electrical problems like overcharging, over discharging or external short circuits, for example.
 
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Travelers. Talk to your independent agent or visit travelers dot com slash Energy. Copyright 2026 The Travelers Indemnity Company. All rights reserved. Travelers and The Travelers Umbrella are registered trademarks of The Travelers Indemnity Company in the U.S. and other countries. This material does not amend, or otherwise affect, the provisions or coverages of any insurance policy or bond issued by Travelers. It is not a representation that coverage does or does not exist for any particular claim or loss under any such policy or bond. Coverage depends on the facts and circumstances involved in the claim or loss, all applicable policy or bond provisions, and any applicable law. Availability of coverage referenced in this document can depend on underwriting qualifications and state regulations.

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Logo: Travelers. Text: BESS Operational Risks: Mitigating Thermal Runaway Risk Across the Lifecycle. Thermal Runaway Prevention. Marek Strojvus, Risk Control Forensic Specialist, Travelers. Marek faces us against a gray background, wearing a navy blue shirt with Travelers Risk Control embroidered on the front. There is a red Travelers umbrella in the upper left corner.

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MAREK STROJVUS: To mitigate the impact of a battery energy storage system fire, focus must be on prevention through proper design, installation and maintenance, with implementation of effective fire suppression and detection systems. Key strategies include adhering to safety standards, ensuring adequate separation distances, utilizing fire-resistant materials and establishing robust emergency response plans.

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Text: System Design and Operational Controls.

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Post-construction, several operational practices can help prevent thermal runaway. Key system design and control measures include real-time monitoring or advanced battery management system, which continuously tracks battery's health like temperature and voltage, enables automated alerts and shutdowns, and communicates data to higher-level control systems, such
 
as SCADA. Next, thermal management -- active cooling using liquid or air systems to maintain safe temperatures and avoid hot spots -- and temperature monitoring, which deploys sensors to detect heat buildup and trigger safety responses. Last, adherence to design operational parameters, running the best within manufacturing-specified charge rates, state of charge and temperature ranges.

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Text: Real-time monitoring. Thermal Management. Adherence to designed operational parameters. Maintenance and Inspection Practices.

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Several maintenance and inspection practices can also be critical, starting with proper maintenance. Following manufacturer's guidelines is not just a suggestion. It is critical to helping prevent thermal runaway. Regular inspections, conducting thermal checks regularly to catch issues early and lastly, vegetation management -- maintain a clear vegetation-free zone to minimize the risk of wildfires spreading to the BESS system.

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Text: Proper maintenance. Regular inspections. Vegetation Management. Human Factors and Emergency Response.

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Consider these steps to address human factors and emergency response. First, training and protocols -- training staff in safe operation and maintenance, establishing clear procedures. Second, risk assessment -- regularly assess risks and plan for extreme weather and emergencies. Third, emergency response -- defining evacuation procedures and communication plans. Lastly, recovery plans -- prepare for incident recovery, including soil and water cleanup and battery disposal.

By prioritizing design integrity, operational vigilance and emergency preparedness, we can help ensure the safe, reliable deployment of battery energy storage systems in the rapidly evolving energy landscape.
 
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Logo: Travelers. Text: Talk to your independent agent or visit travelers dot com slash Energy. Copyright 2026 The Travelers Indemnity Company. All rights reserved. Travelers and The Travelers Umbrella are registered trademarks of The Travelers Indemnity Company in the U.S. and other countries. This material does not amend, or otherwise affect, the provisions or coverages of any insurance policy or bond issued by Travelers. It is not a representation that coverage does or does not exist for any particular claim or loss under any such policy or bond. Coverage depends on the facts and circumstances involved in the claim or loss, all applicable policy or bond provisions, and any applicable law. Availability of coverage referenced in this document can depend on underwriting qualifications and state regulations.

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Logo: Travelers. Text: The Power of BESS Safety Monitoring and Analytics. Analytics as a Safety Layer. Lennart Hinrichs, Executive Vice President and General Manager Americas, TWAICE. Lennart sits in an office with a city visible out the window behind him.

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LENNART HINRICHS: Battery energy storage system risk management includes multiple safety layers. The last one is containment -- physical fire suppression, spacing and structure measures on-site.

The one before that is shutoff. The BMS, or Battery Management System, triggering shutdowns when thresholds are breached. And then the edit layer here is prevention. This includes proactive analytics as an additional layer of intelligence to add to that safety.

Proactive analytics as an extra layer of prevention matter because containment and shutoff mitigate severity but don't prevent root causes. Analytics provide predictive, live, third-layer spotting of issues months before they escalate. This reduces the frequency and scale of potential incidents.

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Text: How Safety Monitoring Works.
 
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A large BESS produces hundreds of millions to billions of data points daily, generating hundreds of thousands to millions of cells. Pinpointing a single failing cell or cooling subsystem amid massive system level data is like searching for a needle in a haystack.

TWAICE system filters noise using statistical anomaly detection and trend analysis. It monitors KPIs like internal resistance, temperature trajectories, cell imbalances and self-discharge.

It classifies alerts by severity -- high, medium, low -- so teams can prioritize response. These analytics provide early warnings, so operational teams can intervene before failure or thermal runaway.

Specifically, they provide a clear root cause diagnostics and recommended actions, for example, isolating cells, inspecting the cooling system or adjusting BMS thresholds.

Automatic reporting and dashboards, on the other side, are tailored to both O&M teams and insurance partners. They can be daily or weekly reports and can include issue notes and KPI tracking.

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The BESS Risks TWAICE Landing Page appears. It has a menu on the left under the heading TWAICE, with sections for Overview, Hierarchy Diagram, Performance, Priority Risk, Monitoring, Health, Warranty, Data Explorer and Reports. At the bottom is the option Collapse. On the bottom right is a blue icon with a white square in it, and a red notification dot in the corner. The Travelers red umbrella logo is on the bottom right of the screen. In the top middle of the landing page are three tabs: BESS Analytics, Simulation Solutions and Professional Services. In the top right are two links: Knowledge Center and Account Settings. Taking up most of the landing page is a Portfolio Overview table, with rows for Cactus in Tucson, US, 300 MWh, 75 MW, Elm in Austin, US, 400 MWh, 100 MW, Oak in London, UK, 24 MWh, 24 MW, and Pine in Canberra, AUS, 20 MWh, 10 MW, and columns titled Performance Status, Safety Index, Penalty Risk and Warranty Status.
 
The table cells have yellow, green, red and gray dots. From top to bottom in the first column, yellow dot, 81.2% of energy is usable, green dot, 92.4% of energy is usable, green dot, 96.8% of energy is usable, red dot, 76.2% of energy is usable. Second column, red dot, action required. Yellow dot, action recommended. Green dot, stable. Green dot, stable. Third column. Red dot, high. Gray dot, onboarding in progress. Gray dot, onboarding in progress. Gray dot, onboarding in progress. Fourth column. Green dot, operation within conditions. Green dot, operation within conditions. Gray dot, onboarding in progress. Green dot, operation within conditions.

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Here's a walk-through of how the TWAICE system flagged a thermal anomaly before it became critical. On the landing page, you can immediately identify the storage system that requires attention. If you set it up, you will also receive an alert via email, for example.

The system continuously applies detection algorithms in the background, but the output is focused and actionable, centering on the three key indicators -- temperature, resistance and self-discharge.

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A BESS Risks page titled Risk Status: Action Recommended versus Action required, page appears. It has the same menu and headers as the landing page. The menu is open to Monitoring, which has two sub-menus: Safety and Smart Alerts. Safety is selected. The Safety Assessment takes up the majority of the page, with a donut chart on the left showing 6 out of 1,160 racks require attention, 1 rack requires action, 5 racks have action recommendations, and 1,154 racks are stable. To the right, the 1 rack with action required and 5 racks with action recommended are called out separately from the donut chart. Below there are sections for Action required and Action recommended. Text: Action required. Rack 12.4.2. This rack shows a severe Temperature anomaly. Action required: Limit the operation of the rack and thoroughly check the functionality of the cooling system. Temperature: anomaly detected. Resistance: stable. Self-discharge: Stable. Open detailed view. Below is the Action recommended section listing racks 13.3.7, 19.4.6 and 24.1.7.

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These are flagged with a risk status, action recommended or action required, depending on the severity. Temperature anomalies often signal secondary issues, such as a cooling system failure or suboptimal design. In this example, one rack is exposed to consistently higher temperatures than peer racks with the same note, so an issue with the cooling system that needs to be resolved is very likely.

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Text: Example: Temperature Anomaly. The section for Rack 12.4.2 expands on the right. Text: Temperature anomaly indicates that this rack is exposed to higher temperatures than similar racks within the same mode. The most likely cause is an issue with the cooling system or a sub- optimally designed cooling system. You can find more information on managing high temperatures within your BESS here. The word Here is a link. If you require support with this, please don't hesitate to reach out to your TWAICE battery expert. Action required: limit the operation of the rack and thoroughly check the functionality of the cooling system. A line graph below is titled Temperature anomaly with a red line for Rack 12.4.2 and a green line for other racks within the same parent component. The x-axis shows the date and the y-axis shows the temperature. The green line is roughly steady low on the graph, but the red line suddenly spikes straight up to the top of the graph on 3/24/20 and continues high.

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Resistance deviations may point to manufacturing defects, internal cell issues or poor connections on the other side.

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Text: Example: Resistance Anomaly. The action recommended sections expand. Text: Rack 13.3.7. This rack shows a temperature anomaly. Action recommended: Investigate the cause of the temperature anomaly, as it is likely related to issues with your cooling system or an inefficient design. Temperature: anomaly detected. Resistance: stable. Self-Discharge: stable. Rack 24.2.5. This rack shows a Self-Discharge anomaly. Action recommended: Monitor the affected rack closely and investigate potential causes of elevated self-discharge, such as internal damage or manufacturing inconsistencies. Consider capacity testing or a detailed cell- level analysis. Temperature: stable. Resistance: stable. Self-Discharge: anomaly detected. Information for Racks 19.4.6 and 24.3.2 go off the screen. On the right is more information for rack 19.4.6, which has a resistance anomaly detected. Text: If you require support with this, please don't hesitate to reach out to your TWAICE battery expert. Action recommended: Perform a detailed inspection to identify potential causes of the resistance anomaly and contact TWAICE experts if further assistance is needed. A line graph below is titled: resistance anomaly detected. It shows a yellow and a green line, yellow labeled Rack 19.4.6 and green labeled other racks within same parent component. The x-axis shows the date and the y-axis shows resistance. The yellow line is consistently above the green line.

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These are critical early indicators of performance degradation and safety risks. The exact cause of the resistance anomaly can range from module and cell internal issues to connection problems, making it essential to identify the root causes of these anomalies.

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Text: Example: Self-Discharge. The section for Rack 24.3.2 expands on the right. Text: If you require support with this, please don't hesitate to reach out to your TWAICE battery expert. Action recommended: Monitor the affected rack closely and investigate potential causes of elevated self-discharge, such as internal damage or manufacturing inconsistencies. Consider capacity testing or a detailed cell-level analysis. A line graph below is titled Self-Discharge Anomaly Detected, with a yellow line labeled Rack 24.3.2 and a green line labeled other racks within same parent component. The x-axis shows the date and the y-axis shows the minimum cell voltage. The green line is consistently high and zigzag while the yellow line is low, smooth and falling to the right.

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Excessive self-discharge often indicates cell degradation or internal defects like lithium plating or electrolyte contamination. Left unchecked, it can cause SOC imbalance, accelerated aging and a heightened thermal risk. Early detection and intervention are crucial to preventing further degradation.

This structured risk classification enables operators to triage alerts, detect emerging safety risks and take timely action.
 
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Logo: Travelers. Text: Talk to your independent agent or visit travelers dot com slash Energy. Copyright 2026 The Travelers Indemnity Company. All rights reserved. Travelers and The Travelers Umbrella are registered trademarks of The Travelers Indemnity Company in the U.S. and other countries. This material does not amend, or otherwise affect, the provisions or coverages of any insurance policy or bond issued by Travelers. It is not a representation that coverage does or does not exist for any particular claim or loss under any such policy or bond. Coverage depends on the facts and circumstances involved in the claim or loss, all applicable policy or bond provisions, and any applicable law. Availability of coverage referenced in this document can depend on underwriting qualifications and state regulations.