As the demand for renewable energy accelerates, Battery Energy Storage Systems (BESS) continue to play a critical role in balancing supply and demand, improving grid resilience, and supporting the integration of solar and wind power.
However, with this progress comes the need to address significant safety challenges associated with high-energy systems, including thermal runaway, gas leaks, explosions and complex maintenance environments.
Through our strong relationships with our channel partners, Fortress, Crowcon, OsecoElfab and Brady, Teksal Safety is in a unique position to support safe, reliable BESS, across a range of industries and applications.
We do this by delivering integrated, fit-for-purpose solutions that protect people, plant and processes throughout the BESS lifecycle, from manufacturing to ongoing maintenance.
Let’s take a closer look at how we do this with each channel partner, and respective applications in Australia.
Fortress Safety – interlocking solutions for BESS
BESS involve complex electrochemical processes that require strict access control and safety interlocks to ensure safe operation. Fortress Safety’s robust mechanical and electromechanical interlocking systems are designed to protect operators during activities like maintenance and module replacement.
In environments such as gigafactories or large-scale storage installations, Fortress’ interlocks ensure hazardous energy sources, like high-voltage switchgear, cannot be accessed or switching operations conducted until it’s safe to do so.
We support our clients by integrating Fortress solutions into BESS, helping reduce the risk of human error, while ensuring compliance with safety standards.
Application: For example, we supply and install switchgear interlocks to protect people working with electrical distribution systems. As more BESS are integrated into renewable energy projects, our approach for traditional networks is transferrable to the new setting.
Crowcon – early gas detection for lithium-ion battery safety
One of the most serious risks in BESS is thermal runaway – an event that can release flammable and toxic gases before escalating into fire or explosion. Through our partnership with Crowcon, we deliver gas detection solutions that provide early warning of gas build-up inside battery enclosures or surrounding areas.
Crowcon’s BESafe range is specifically designed for BESS applications, offering fixed and portable gas detectors that identify early signs of electrolyte leakage or cell off-gassing. These systems allow operators to take swift corrective action, preventing catastrophic failures and ensuring safer working environments.
Why it matters: Crowcon’s sensors are crucial for early intervention—often providing the only alert before more severe battery failure events occur.
OsecoElfab – explosion protection for BESS enclosures
In the rare but serious event that gas buildup goes undetected, explosion mitigation is critical. OsecoElfab, a leader in pressure relief and explosion protection, provides venting solutions engineered to relieve pressure safely in lithium-ion battery storage systems.
Teksal Safety incorporates OsecoElfab’s rupture discs and explosion panels into BESS cabinets and containers, ensuring that any overpressure is directed away from personnel and infrastructure. These passive safety devices offer a final line of defence, particularly in high-density systems where thermal events can propagate rapidly.
Application: OsecoElfab’s battery-specific designs are compliant with UL9540A and other global fire testing standards, making them an essential component in any compliant BESS design.
Brady – Hazard identification, lockout/tagout and labelling
Managing electrical hazards, access procedures, and maintenance workflows in BESS requires clear communication and rigorous process controls.
Through our relationship with Brady, we provide comprehensive solutions for hazard identification, energy isolation and facility labelling, including:
- Lockout/tagout (LOTO) systems for isolating high-voltage components during maintenance
- Durable safety signage and cable labelling for easy identification of system components
- Customisable visual management tools to ensure staff are aware of potential risks and protocols
Brady’s systems help enforce a culture of safety, reduce downtime, and support compliance with Australian and international standards for workplace safety.
Our holistic approach to BESS safety
With our in-depth understanding of Australian industry requirements and access to world-class safety products, we support companies designing, building and operating battery energy storage systems.
By combining Fortress’ interlocking solutions, Crowcon’s gas detection solutions, OsecoElfab’s explosion protection products, and Brady’s identification and control systems, we offer integrated solutions that address BESS safety across a range of contexts.
Whether you’re building a new grid-scale storage facility or retrofitting safety into an installation, we work collaboratively with clients to tailor safety solutions that reduce risk, enhance performance, and ensure compliance.
For more information about how Teksal Safety can support your BESS, get in touch.
