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Race to develop shipboard EV fire early detection systems

Survitec A fire
Prevention and control of lithium-ion battery fires has become a safety concern in the maritime industry, leading to a drive to develop early warning systems to prevent disaster.

Lithium-ion battery fires can escalate very quickly, reaching very high temperatures much more quickly than a comparable fire from more standard fuels like oil and petroleum. The intensity of a lithium-ion battery fire and the location of electric vehicles’ batteries makes fighting such fires difficult on land and even more so at sea.

Vessels carrying electric vehicles, from ferries to Pure Car and Truck Carriers (PCTCs), are at risk of real risk of total loss if a battery fire becomes established.

One avenue mitigating the risks of carrying EVs is detecting the early signs of a potential battery fire, as before igniting lithium-ion batteries often vent gases and smoke, generate heat, and make popping sounds.

“Any slight deviation in [battery] properties can provide an early indication that conditions are right for a fire and afford time to take preventative measures to protect or quarantine hybrid and EVs,” according to safety equipment manufacturer Survitec.

Early fire detection solutions are on the market, but not yet adapted to identify the pre-ignition behaviours of lithium-ion batteries, said Rafal Kolodziejski, Survitec’s Head of Product Support & Development - Fire Systems.

“Monitoring car decks for early-stage fire conditions – typically any fluctuation in temperature or atmospheric condition – is critical to preventing fire propagation. The type and location of sensors are vitally important.”

Kolodziejski said that Survitec is investing “heavily in the development of new solutions capable of pre-ignition monitoring” and is working with a major ship operator to design a comprehensive fire detection and extinguishing system for the EV cargo deck of a new build PCC (Pure Car Carrier).

Currently in development, the company’s integrated graphical monitoring system can provide real-time status of all the fire-protected zones onboard. The monitoring system will link all the detection systems and sensors onboard to allow for the remote or local activation of a compartment’s fire suppression system.

The rapid increase in intensity of EV fires creates added danger for crews, who are traditionally expected to visually confirm a fire before raising the alarm. In a situation with venting toxic gases and high temperatures, exposure even for a brief period of time could cause serious harm. Smoke clouds also quickly limit the efficacy of CCTV systems.

“An EV battery fire is different to any other type of fire in that the battery generates explosive and toxic gases, increasing the size and propagation of the fire,” explained Kolodziejski.

“The heat is, therefore, more intense, and an extinguished fire can potentially reignite at any time until the battery is completely burnt down. This presents a real challenge regarding gas-based fixed fire systems, such as CO2. Traditionally, a system pack has sufficient gas for just one discharge in the event of a fire. Currently, classification societies propose that double the gas volume is provided, but this may not be enough to control fire or prevent reignition," he continued.

Listen to an episode of the Seatrade Maritime Podcast on fire safety on car carriers and containerships

Cooling runaway batteries using vast volumes of water is among the tools used on land, but with batteries commonly located on the underside of a vehicle, getting water to the area it is needed is a challenge, especially in tightly packed car decks. Water volume requirements for cooling EV fires also pose a real risk to vessel stability.

“EV car-carrying ship owners are urged to consider increasing the space between each vehicle or reducing the number of units transported. Some ship operators are already requesting that batteries in used or second-hand EVs are disconnected prior to shipment, especially if EVs or their batteries show signs of damage,” said Survitec.

“Prevention is certainly better than the cure at the moment,” said Kolodziejski. “Early monitoring and detection are becoming increasingly important safety factors for ship operators and crew. With an EV cargo, the earlier the crew can detect pre-fire conditions, the better.”