Case Background
With the large-scale implementation of electrochemical energy storage, new energy power stations, hydrogen energy storage and photovoltaic supporting energy storage projects, energy storage safety has become a core focus of industry supervision. Typical energy storage scenarios include prefabricated cabin battery energy storage stations, containerized energy storage systems, battery PACK workshops, hydrogen storage systems and new energy charging & swapping stations. These scenarios feature enclosed cabins, high-density battery cells, long-term unattended operation, thermal runaway chain reactions and flammable & explosive hydrogen. In accordance with the Safety Code for Electrochemical Energy Storage Power Stations and Fire Technical Standard for Energy Storage Power Stations, the core requirements and pain points of gas monitoring in this industry are listed below:
1.1 Hidden Early Gas Risks of Battery Thermal runaway Prone to Severe Accidents
Lithium-ion batteries may suffer thermal runaway chain reactions under overcharging, overheating, short circuit, extrusion and aging faults. Carbon monoxide, hydrogen and VOC volatile organic gases are released in the early fault stage, followed by massive flammable gas eruption in later stages. The enclosed energy storage cabin prevents natural gas diffusion, leading to rapid gas accumulation. Once reaching the explosive limit, gas may ignite and cause combustion, explosion, re-ignition and cascading fire accidents triggered by electrical sparks. Traditional temperature and smoke monitoring suffers severe lag and only triggers alarms after fire breaks out, failing to realize early prediction. This constitutes the primary trigger for major safety accidents in energy storage stations.
1.2 Extremely High Leakage Risk of Hydrogen Energy Storage with Wide Explosion Coverage
For hydrogen energy storage, hydrogen storage tanks and hydrogen fuel cell supporting systems, hydrogen has an explosive limit of 4%–75%VOL, the widest range among flammable gases. Hydrogen is colorless, odorless, fast-diffusing and highly penetrative. Slight aging of pipeline joints, valves and seals can cause tiny leaks, and hydrogen accumulates rapidly inside enclosed energy storage cabins. Conventional monitoring devices have slow response and insufficient sensitivity and cannot capture early micro-leakage, bringing huge combustion and explosion hazards.
1.3 Complex Cabin Environment Causes False Alarms, Missed Alarms and Sensor Drift & Failure
Energy storage cabins have complex internal environments including electrolyte volatilization, siloxane contamination, temperature & humidity fluctuations and electromagnetic interference. Ordinary gas sensors are vulnerable to cross-interference, resulting in false alarms and sensitivity drift. Meanwhile, energy storage projects require 7×24-hour continuous operation with a service life of more than 10 years. Conventional detectors have poor anti-poisoning and anti-interference performance and low long-term stability. Frequent failures and calibrations lead to monitoring gaps and safety blind spots.
1.4 Unattended O&M Mode Lacks Intelligent Early Warning and Linkage Mechanism
Large-scale energy storage power stations mostly adopt remote unattended operation. Traditional monitoring only supports local alarms without remote push, intelligent analysis or equipment linkage. Minor concentration changes of gas in the initial thermal runaway stage cannot be identified, so hazards keep accumulating. By the time smoke or temperature anomalies appear, irreversible thermal runaway has already occurred, making early detection, disposal and loss control impossible.
1.5 Strict Industry Compliance and Mandatory Requirements for Data Traceability and Closed-loop Management
Current energy storage safety codes explicitly require gas early warning devices for energy storage cabins, battery rooms and hydrogen storage zones to realize full-process monitoring, data retention, fault traceability and fire system linkage. Most old stations suffer from insufficient monitoring points, substandard equipment, missing data ledgers and incapability of linkage control. They cannot pass safety acceptance and regular inspections, exposing enterprises to compliance rectification risks.
Taizhi Solutions
This solution is deeply adapted to the unique operating conditions of electrochemical energy storage, hydrogen energy storage and new energy charging & swapping stations. Targeting five core pain points including early thermal runaway prediction, hydrogen leakage monitoring, enclosed gas accumulation, equipment false alarm interference and unattended management, it builds an integrated energy-storage gas safety solution combining high-precision fixed-point cabin monitoring, zoned grid deployment, AI intelligent analysis & early warning, fire & ventilation linkage and cloud-based data traceability. Focused on the core objectives of early warning, rapid disposal, re-ignition prevention and cascading explosion prevention, it upgrades safety management for battery thermal runaway and hydrogen leakage from passive fire suppression to proactive prediction and pre-emptive risk control.
2.1 Overall Architecture
The solution adopts a hierarchical and zoned architecture for precise risk prevention, fully matching the characteristics of enclosed energy storage cabins and high-density equipment layout:
Front-end Sensing Layer: Anti-interference dedicated gas detectors are deployed in a distributed manner at key positions such as prefabricated energy storage cabins, gaps between battery clusters, cabin tops, hydrogen storage cabinets and pipeline valve groups. They accurately monitor thermal runaway characteristic gases including hydrogen, carbon monoxide and VOCs to realize refined zoned monitoring and eliminate monitoring blind spots.
Transmission & Linkage Layer: Industrial-grade anti-interference transmission is adopted to upload concentration data and device status in real time. The system can directly link cabin exhaust fans, emergency power-off devices and fire suppression systems to trigger automatic ventilation, power cut and fire-fighting actions upon concentration exceedance.
Intelligent Analysis Layer: Powered by AI algorithms, the system filters interference signals from electrolyte, ambient water vapor and other sources. It accurately distinguishes real leakage and thermal runaway hazards from environmental interference to avoid false and missed alarms, and supports multi-level threshold alerts (pre-warning, low alarm and high alarm).
Cloud Management Layer: It aggregates full-domain monitoring data to realize real-time display, curve analysis, remote alert push, historical traceability and automatic report generation, meeting the requirements of remote operation for unattended power stations, compliance ledger management and closed-loop hazard control.
2.2 Core Deployment Logic
Following the principle of hierarchical zoning, focused deployment and early prediction, dense grid-style measuring points are arranged inside battery cabins to capture trace gases generated by early cell thermal runaway. High-sensitivity hydrogen detectors are prioritized in hydrogen storage areas to guard against micro-leakages. Portable inspection equipment is equipped at the station for daily hazard re-verification and point calibration, forming a dual protection system of fixed monitoring plus mobile recheck.
2.3 Core Advantages of the Solution
It specifically addresses the energy storage industry’s pain points including sensor susceptibility to interference, drift, delayed warning, lack of linkage capability and non-traceable data. Featuring anti-silicon poisoning, anti-cross-interference, low long-term drift and ultra-long service life, it meets the requirement of 10-year continuous operation for energy storage sites and fully complies with national safety acceptance standards for energy storage.
Impl. Results
3.1 Realize Advanced Prediction of Thermal Runaway and Prevent Severe Combustion & Explosion Accidents
Overcoming the inherent lag of traditional temperature and smoke detectors, the system captures subtle concentration changes of characteristic gases at the incipient gas-generation stage of battery thermal runaway, sending warnings several minutes to tens of minutes earlier than temperature rise and smoke sensors. It reserves sufficient time for manual intervention, equipment shutdown, ventilation cooling and fire response. It effectively blocks chain thermal runaway triggered by single-cell faults, completely preventing catastrophic accidents such as cascading fire, explosion and re-ignition in energy storage cabins, and fundamentally improving the intrinsic safety of energy storage sites.
3.2 Precisely Filter Interference Signals and Eliminate False and Missed Alarms
Equipped with energy-storage-specific AI filtering algorithms and anti-interference sensing technology, the system effectively suppresses false signals caused by electrolyte volatilization, siloxane contamination, temperature & humidity fluctuations and electromagnetic interference, and accurately identifies genuine gas leakage and thermal runaway hazards. It thoroughly solves the prevalent industry problem of disruptive false alarms and unreported hidden risks, greatly boosting monitoring accuracy and ensuring long-term stable equipment operation, avoiding unnecessary shutdown maintenance and wasted O&M expenses caused by false alerts.
3.3 Full-coverage Precise Prevention & Control of Hydrogen Leakage to Eliminate Explosion Hazards
Targeting the features of hydrogen energy storage including high pressure, fast diffusion and concealed leakage, high-sensitivity hydrogen detectors are deployed to capture ppm-level micro-leakages and predict risk accumulation in advance. Combined with zoned monitoring, the system quickly pinpoints leakage locations and links with ventilation systems to dilute gas rapidly, preventing hydrogen concentration from approaching the explosive limit. It delivers comprehensive safety protection covering hydrogen storage cabinets, pipelines and fuel cell systems.
3.4 Intelligent Linked Closed-loop Disposal Enables Efficient Unattended Management
The system supports multi-level early warnings and fully automatic linkage. Minor exceedances trigger automatic ventilation and alert notifications; severe exceedances activate emergency power cut, air-conditioning shutdown and fire suppression devices, realizing fully automatic emergency response for unattended sites. Pre-emptive hazard disposal can be completed without manual intervention, greatly reducing O&M workload and fitting the unmanned and intelligent operation mode of large-scale energy storage stations.
3.5 Full-cycle Data Retention to Fully Meet Compliance Acceptance Standards
Devices continuously and stably collect data 7×24 hours. Monitoring curves, alarm logs, equipment status and linkage records are automatically retained throughout the whole process. Data is stored permanently, tamper-proof and available for traceability and export at any time. Fully meeting compliance requirements for safety acceptance, regular inspections and O&M audits of energy storage power stations, it resolves common site issues including non-standard monitoring, missing ledgers, data gaps and failed acceptance.
3.6 Ultra-long Stable Operation and Greatly Reduced O&M Costs
Specially designed for long-term O&M conditions of energy storage, the devices feature anti-poisoning, low drift and long service life, matching the site service cycle of over 10 years without frequent calibration or sensor replacement. Compared with conventional ordinary detectors, the failure and repair rates are significantly reduced, effectively cutting costs for manual inspection, equipment maintenance and shutdown rectification, and satisfying the lightweight O&M demands of energy storage power stations.
Solution Value
4.1 Safety Value: Pre-empt Thermal Runaway and Secure Station Safety Bottom Line
By adopting early gas prediction technology, the solution builds the first safety warning barrier for energy storage stations. It effectively blocks chain reactions of battery thermal runaway, eliminates major accidents such as fire, explosion, equipment damage and full-station shutdown, safeguards station assets and power grid stability, and avoids tens of millions of accident losses and public opinion risks.
4.2 Compliance Value: Full Standard Compliance to Avoid Rectification and Shutdown Risks
Fully aligned with mandatory national standards including the Safety Code for Electrochemical Energy Storage Power Stations, the solution realizes full coverage of monitoring points, complete early warning mechanisms, intact linkage functions and compliant data traceability. It supports one-time passing of safety acceptance, grid-connection inspection and annual supervision, thoroughly eliminating compliance risks such as repeated rectification, operation suspension, traffic restriction and filing abnormalities.
4.3 O&M Value: Intelligent Cost Reduction and Efficiency Improvement for Unattended Operation
Intelligent early warning, automatic linkage and self-diagnosis functions greatly reduce manual inspection frequency and on-site workload. With long-term stability, low failure rate and minimal data drift, the devices cut calibration and replacement costs. Remote visual management enables operators to grasp full-site safety status remotely, realizing lightweight and intelligent upgrading of energy storage safety operation and maintenance.
4.4 Asset Value: Ensure Continuous Operation and Improve Revenue Stability
The solution effectively prevents shutdowns, maintenance and rectification caused by safety hazards and equipment faults, ensuring stable revenue from grid connection, peak regulation, frequency modulation and power trading of energy storage stations. It reduces equipment burnout and asset scrapping loss, extends the overall service life of energy storage systems, and maximizes the return on investment of power stations.
4.5 Industry Value: Standardized Safety System to Boost Large-scale New Energy Development
It establishes a replicable and implementable standard system for gas safety prevention and control in energy storage scenarios, solving industry pain points including difficult thermal runaway early warning, high false alarm rate and weak safety management. It supports the safe, standardized and large-scale development of the new energy storage industry and enhances enterprises’ core competitiveness in energy storage project bidding and safety evaluation.
Equip. Intro
This solution’s supporting equipment is specially developed for enclosed energy storage cabins, complex interference and long-term unattended operating conditions. Featuring anti-silicon poisoning, anti-cross-interference, low drift, long service life and high explosion-proof performance, it is fundamentally different from ordinary industrial gas detectors. The core equipment is introduced as follows:
5.1 Fixed Composite Gas Detector Dedicated for Energy Storage Custom-developed for electrochemical energy storage cabins and battery rooms, it supports composite multi-gas detection of hydrogen, carbon monoxide and VOCs, precisely matching the gas generation characteristics in the early stage of battery thermal runaway. Equipped with dedicated anti-interference sensor chips and AI algorithms, it effectively filters interference from electrolyte volatilization, siloxane, temperature & humidity and electromagnetic disturbance to eliminate false alarms. The device boasts IP67 high protection rating and Ex d IIC T6 explosion-proof certification, suitable for enclosed, humid, dusty and strong-electromagnetic cabin environments. It enables stable 7×24-hour continuous operation with low drift and meets the 10-year service requirement of energy storage sites. Capable of direct linkage with ventilation, power cut-off and fire fighting systems, it serves as the core early warning device for energy storage stations.
5.2 High-sensitivity Dedicated Hydrogen Detector Designed for hydrogen energy storage, hydrogen storage cabinets and hydrogen fuel systems, it addresses hydrogen’s properties of fast diffusion, concealed leakage and wide explosive range. With ultra-high sensitivity, it identifies ppm-level micro-leakages and delivers extremely fast response. Resistant to gas cross-interference and high-pressure conditions, it operates stably in enclosed high-pressure hydrogen storage environments to capture early leakage hazards and prevent excessive gas accumulation, fully complying with safety monitoring specifications for hydrogen energy storage.
5.3 Portable Energy Storage Gas Detector For routine station inspection, fault re-verification, thermal runaway hazard screening and equipment calibration & acceptance. Lightweight, explosion-proof and user-friendly, it simultaneously measures core parameters including H₂, CO and VOCs. Built with a precision sampling pump, it can conduct sampling deep into gaps between battery clusters and enclosed dead zones to compensate for limitations of fixed-point monitoring, quickly locating concealed leaks and abnormal hazards. It applies to the full lifecycle of energy storage site operation, maintenance and acceptance.
5.4 Dedicated Alarm & Linkage Controller for Energy Storage As the core on-site regional management device, it centrally receives signals from all detectors and supports independent threshold configuration for each zone to meet the management requirements of multiple cabins and units. It features local audible & visual alarms, data storage, fault prompts and linkage output. It can work independently during network or power outages and directly connect to fans, sprinklers, emergency power-off and fire systems to realize fully automatic on-site emergency linkage, ensuring safety and controllability under unattended operation.
5.5 Intelligent Cloud Platform for Energy Storage Safety Monitoring Specially adapted for safety management of energy storage stations, it supports centralized management of multiple sites and cabins. Integrated functions include real-time data monitoring, AI thermal runaway prediction, multi-level remote alarms, equipment fault diagnosis, historical curve traceability, automatic compliance reports and maintenance ledger management. Remote access is available via mobile phones and PCs. Data is permanently stored on the cloud and tamper-proof. It can seamlessly connect with energy storage station O&M platforms and power grid safety supervision systems to realize digital, intelligent and closed-loop management of gas safety for energy storage.
