Energy Risk Engineering

The new generation of ion-exchange membrane chlor-alkali plants (2024–2030 generation) is delivering 25–35% more energy-efficient operations thanks to advances like higher current densities and oxygen-depolarized cathode (ODC) designs. However, this shift dramatically changes the risk profile, as higher current densities, thinner membranes, and increased automation amplify certain loss scenarios that were previously negligible. This description breaks down the leading hazards for new-build membrane plants. We detail the Top Eight Emerging Major Accident Hazards (MAH), including the risks of massive hydrogen-in-chlorine crossover leading to cell-room explosion, thermal runaway due to brine depletion, and cyber intrusion causing rectifier overload. Finally, we summarize the best-practice mitigation benchmarks—such as independent low-low brine flow trips and redundant online moisture analyzers—that owners and insurers recognize, which can materially improve safety, reduce risk, and help cap Maximum Foreseeable Loss (MFL) scenarios below US$450 million.

The Invisible Threat: Detecting High-Voltage Corona DischargeEvery utility faces a major hidden danger that leads to outages, equipment failure, and even wildfires: corona partial discharge, the invisible electrical glow that slowly destroys high-voltage components. In this episode, we welcome Michael Kelly and Dale Morrison from OFIL Systems, the global leader in UV-based corona detection, to break down this silent threat.Learn what corona is—an electrical leak caused when the electric field ionizes the air—and why it’s the "check engine light" for the entire grid. We dive into the groundbreaking technology that makes the invisible visible: OFIL’s cameras use a patented solar-blind filter to capture the corona's specific UVc light signature, allowing utilities to pinpoint discharges hundreds of feet away, even in bright daylight.Discover why proactive inspection is now essential, driven by aging infrastructure, rising wildfire risk, and the demands of regulators and insurers. Find out how combining UV detection with thermal imaging and ultrasound creates the "Tri-fecta" of predictive maintenance, helping utilities build safer, more resilient systems. If you can SEE it, you can FIX it before it fails.

Effective Standard Operating Procedures (SOPs) are non-negotiable in the energy sector, particularly when managing high-hazard materials like Liquefied Natural Gas (LNG) and Liquefied Petroleum Gas (LPG). These detailed guidelines are foundational for ensuring safety and managing emergency response during leaks and fires.Our procedures emphasize strict general precautions, requiring responders to approach the incident from upwind and immediately evacuate all personnel from the path of the vapor cloud. A key focus for LPG handling is the severe possibility of a BLEVE (Boiling Liquid Expanding Vapor Explosion) if fire impinges on an unprotected tank shell above the liquid level, necessitating careful fire control strategies.The SOPs outline specific control methods tailored to the unique properties of these cryogenic vapors and liquids. This includes mandating that personnel wear proper protective clothing and self-contained breathing apparatus, utilizing specialized materials like Hi-ex foam for LNG spill coverage or fire radiation control, and employing water spray monitor nozzles for effective vapor cloud dispersion while strictly avoiding applying water directly to large pools of LNG or LPG, which intensifies vaporization. Following these protocols precisely helps limit damage and protect life by ensuring controlled responses to dynamic, hazardous situations.

This document, titled "Post-Incident Analysis: Lessons from $1.5B+ Li-Ion BESS Losses," offers a crucial look into the safety challenges facing the rapidly expanding Battery Energy Storage System (BESS) industry. Authored by John Munno in November 2025, the analysis highlights the severe risks that have emerged as BESS capacity skyrocketed from 5 GW in 2020 to 54 GW in 2025.Key Takeaways and Scope:The report investigates over 50 major BESS fires between 2020 and 2025, which collectively resulted in total losses exceeding $1.5 billion—covering property damage, downtime, and cleanup costs. Crucially, these incidents also incurred a devastating human toll, contributing to more than 10 deaths and 50 injuries globally.The analysis examines high-profile incidents across North America, East Asia, Europe, and Australia. Specific case studies reveal systemic failures and profound environmental and safety impacts:• Moss Landing, California (January 2025): A fire at the Vistra 300 MW facility—the world's largest—caused over $100 million in damages. Investigations suggested cell defects or overheating exacerbated by dense packing, and found that clean agent suppression failed to cool the cells. Post-incident soil and water tests confirmed elevated levels of cobalt, nickel, and manganese (heavy metals) that exceeded EPA levels, resulting in health complaints and contamination risks.• Moorabool, Australia (Victorian Big Battery, July 2021): This fire, which occurred during commissioning, was traced to a coolant leak that caused a short circuit and subsequent thermal runaway. The firmwares lacked essential isolation alarms, leading to rapid propagation.• Beijing, China (April 2021): An explosion during response efforts resulted in two firefighter fatalities. The cause was identified as cascading thermal runaway combined with poor ventilation, which allowed explosive gases (H2, CO) to build up.Root Causes and Recommendations:The source identifies common themes and root causes driving these catastrophic failures:1. Thermal Runaway Triggers: 60% of incidents stemmed from defects or overcharge, while leaks accounted for 30%.2. Propagation Modes: Fires typically spread via heat conduction through cell shells and by the release of explosive atmospheres generated by gases like H2 and HF.3. Mitigation Failures: While suppression systems (like clean agents) can put out flames, they often fail to provide necessary cooling to prevent thermal runaway cascades.The report concludes with critical lessons emphasizing Prevention Over Reaction and the need for Layered Defenses:• Technology & Monitoring: Battery Management Systems (BMS) must be updated to monitor at the cell level to isolate anomalies early (a lesson learned after the Moorabool fire).• Suppression: No single suppression method is sufficient; systems must combine detection, venting, and cooling, recognizing that water-based suppression, though risking shorts, is effective in prolonged events (like the Chandler, Arizona, fire).• Safety & Environment: There is a mandate to monitor toxic releases (such as HF and heavy metals) and implement secondary containment for runoff to manage environmental contamination, a key finding following the Moss Landing incident.• Response: Emergency Response Plans (ERPs) must specifically address deflagration risks, and remote tools or robots should be utilized for high-risk actions.Overall, this analysis stresses that the rapid scaling of BESS technology is currently outpacing safety standards and requires urgent, international failure data sharing and mandatory site-specific Hazard Mitigation Analyses (HMA).

Dive into the world of solar energy innovation with this episode on "Electrical Signature Analysis for Solar Photovoltaic Monitoring." Discover how ESA—a cutting-edge, non-invasive technique—revolutionizes fault detection in PV systems by analyzing current-voltage curves to spot issues like loose connections, hot spots, and inverter inefficiencies before they escalate. We break down its applications in massive utility-scale farms versus everyday residential setups, compare it to thermal imaging, and explore real case studies where ESA prevents fires and boosts reliability. Whether you're a renewable energy pro or just curious about sustainable tech, this deep dive highlights tools like the Fluke PVA-1500 and FLIR PV48, grounded in IEC standards, to keep solar power shining bright. Tune in for expert insights on reducing downtime and safeguarding the future of clean energy!