Transcript Update on the Navy’s Lithium Battery Safety Program

Julie Banner
Code 616
Naval Surface Warfare Center
Carderock Division
System Safety Society WDC Chapter Mtg
16 March 2011
 Information included in this presentation is
unclassified
 The purpose of this presentation is to provide
general information covering
–
–
–
–
Basic introduction to lithium battery technology
General hazards associated with lithium batteries
Firefighting methods and lithium batteries
Recent developments in the Navy’s Lithium Battery Safety
Program
 Some of the images shown in this presentation
are the extreme results of aggressive and
deliberate battery abuses
3/15/11
NSWC Carderock Code 616
2
 Battery Types
– Primary
 Battery Chemistries
– Cathode
• Active
• Reserve
– Liquid Reserve
– Thermal
– Secondary
 Cell Designs
– Bobbin
– Spiral
– Bipolar
– Coin
– Prismatic
3/15/11
• Manganese
Dioxide
• Carbon
Monofluoride
• Thionyl Chloride
• Sulfur Dioxide
• Sulfuryl Chloride
• Vanadium
Pentoxide
• Cobalt Oxide
– Anode
• Lithium Metal
• Lithium Alloy
• Lithium Ion
– Electrolyte
• Organic Liquid
• Polymer/Gel
NSWC Carderock Code 616
 Cell Sizes
– Button Cell
(0.01 Ah)
– AA-Size Cell
(2 Ah)
– D-Size Cell
(10-20 Ah)
– Specialty
Design Cell
(2,200 Ah)
– Air Force
Design Cell
(10,000 Ah)
3
From Handbook of Batteries, 3rd Edition, by Linden and Reddy
3/15/11
NSWC Carderock Code 616
4
Lithium Ion
Zn-air
Specific Energy, Wh/kg
3/15/11
NSWC Carderock Code 616
1375 Wh/kg = TNT
5
3/15/11
NSWC Carderock Code 616
6
 Controlled Release of This Energy
Provides Electrical Power in the Form of
Current and Voltage
 Uncontrolled Release of This Energy can
Result in Venting, Fire, Release of Toxic
Materials, Shrapnel, High Pressure Events,
Deflagration (with or without Report) and
Many Combinations Thereof
3/15/11
NSWC Carderock Code 616
7
Venting
Leaking of hazardous materials
– Noxious or acidic gases
– Strong acids
– Flammable gasses and liquids
Fire
Note: Other types of batteries may also respond to
abusive conditions presenting similar (but not
identical) hazards, so many of the handling and
safety recommendations that follow can be
considered to be appropriate for all battery types
3/15/11
NSWC Carderock Code 616
8
 Release of internal pressure from a cell by
ejecting some or all of its internal components
into the environment
– These components may be flammable and may include
noxious gasses
– A venting of a lithium ion battery may release
•
•
•
•
•
•
Flammable organic electrolyte (e.g. PC-EC-DMC)
LiPF6 -- this material is reactive with H20 and forms HF
Carbon either as carbon or water reactive lithiated graphites
LiNiCoO2 or other lithiated oxides and heavy/transition metals
Metal foils and fragments (copper or aluminum)
Methane, hydrogen, carbon monoxide (electrolyte
decomposition products)
 Ventings may be accompanied by smoke, sparks
and or flames
 Ventings may be high pressure events
3/15/11
NSWC Carderock Code 616
9
 Release of internal pressure from a cell by
ejecting some or all of its internal components
into the environment
– A venting of a Li/SOCl2 battery may release
• Lithium Metal (Li) - reactive in air & highly reactive in H2O
• Thionyl Chloride (SOCl2) - combines immediately with any
moisture to create fumes of HCl and SO2
• Carbon (C)
• Aluminum Chloride (AlCl3)
• Lithium Chloride (LiCl)
• PVC
• PTFE (teflon)
 Ventings may be accompanied by smoke, sparks
and or flames
 Ventings may be high pressure events
3/15/11
NSWC Carderock Code 616
10
 Physical abuse, such as crushing, puncturing or
burning
 Overcharging a rechargeable lithium battery (due
to electronics failure)
 Charging of primary (non-rechargeable) batteries
 Exposure of battery to inappropriate environment
– High temperature abuse (140°C)
– Water immersion of an unprotected or unsealed battery
 Short circuit or abnormally high rate discharge of
battery
 Unanticipated latent manufacturer’s defect
failure
3/15/11
NSWC Carderock Code 616
11
 Puncturing and crushing result in massive
internal short circuits that are not
mitigated by external or internal safety
devices and frequently result in thermal
runaway and violent venting of lithium
batteries with incandescent ejecta
 Recommendation: Whenever possible,
package lithium batteries in protective
containers and be aware of potential
physical hazards
3/15/11
NSWC Carderock Code 616
12
 Lithium ion batteries may be designed to be
recharged either inside or outside their system
housing
 Redundant over-voltage and over-current
electronics “should” prevent abuse due to
overcharging
 In abuse tests of high energy lithium ion cells and
similar modules, cells vented with pressure and
flame in response to extreme overcharging
conditions
 Recommendation: Always follow standard
operating procedures and manufacturer
recommendations for charging the battery
3/15/11
NSWC Carderock Code 616
13
 Use of battery in circuit with very low (<50 milliohms or
less) resistance
 Short circuits can be caused by
– Connecting positive and negative terminals of battery (External, i.e.
“crowbar” or loose wires or screwdriver)
– Breaching physical integrity of battery (Internal)
 Fuses and other over-current electronics “should” prevent
abuse due to external short circuits
 Some lithium cells include internal safety devices to protect
against overcurrent conditions
 Precautions include
– Do not handle battery modules on metal surfaces
– Keep terminals insulated and separated
– Never remove or bypass electrical fuses
3/15/11
NSWC Carderock Code 616
14
 System-specific guidance included in system emergency
documentation
 General shipboard guidance given in S9086-S3-STM-010
“Naval Ships’ TM Chapter 555 - Volume 1 Surface Ship
Firefighting” Vol 1 Rev 13 of 1 Jan 2010, section 8.14
– Application of a narrow-angle fog of water or AFFF is the preferred
method to cool the battery, suppress immediate fire output, and
reduce likelihood of propagation to remaining cells
– Maintain an adequate distance for personnel safety from exposure
to fireballs and/or projected fragments
– Personnel should wear SCBAs to protect from exposure to
hazardous gases (acid gases, oxidizers and other toxic and
irritating materials)
– Continue to cool the battery for several minutes after the last cell
event and do not approach until there is evidence that all reactions
have stopped
– Initiate active desmoking/ventilation of the area as soon as
practicable during the casualty to remove heat, smoke and toxic
gases
3/15/11
NSWC Carderock Code 616
15
 Instruction -- Defines the Process
–
–
–
–
–
NAVSEAINST 9310 Initial Release in 1979
NAVSEAINST 9310.1a of 11 March 1982
NAVSEANOTE 9310 of 11 June 1985
NAVSEAINST 9310.1b of 13 June 1991
NAVSEAINST 9310.1c revision in review at NOSSA
& planned for an FY11 release
 Technical Manual -- Guidelines for Design,
Review and Procedures for Testing
– Technical Manual for Batteries, Navy Lithium Safety
Program and Procedures, Rev 2 S9310-AQ-SAF-010
of 15 July 2010
 https://nossa.nmci.navy.mil/nrws2/tabid/232/
Default.aspx
3/15/11
NSWC Carderock Code 616
16
 Navy Lithium Battery Safety Authorizations are
system specific
 Authorizations for previously reviewed batteries:
– Leverage data from previous programs (testing, analysis,
design) when appropriate
– Do not required duplicative testing
– Are usually quicker
 Contact NOSSA, Carderock or Crane to determine
if a battery has previous safety reviews on file
3/15/11
NSWC Carderock Code 616
17
 Originally granted to NAVSEA Safety Division (NAVSEA
665), and has followed the Explosive Safety Office through
multiple reorganizations
 Currently resides with Code N84 of the Naval Ordnance
Safety and Security Activity, under the auspices of the
Explosive Safety Office for Navy Systems
 Special Authority for specific platform use
– NAVSEA Code 05Z34 for Surface Ship & Submarine Carriage
– MSCHQ for Military Sealift Command platforms
– NAVAIR 4.4.5.2 for Aircraft Carriage
 Primary testing and evaluation sites
– Carderock Division, NSWC, Code 616
– Crane Division, NSWC, Code GXS
3/15/11
NSWC Carderock Code 616
18
 Official documentation (signed) is the NOSSA Interim
Letter of 2 April 09
 SEA05Z34 proposed process is contained in draft TM
“High-Energy Storage System Safety Manual”
– Released 9 Jul 10 for review
– Revised version has been in review by SEA05 (Mr. Drakely
and ADM Eccles) for past few months
– Under a mandatory 15 day SEA05Z34 official standards
review
 Staged implementation of SEA05 TM is planned
– New manual will be implemented on new system starts as of
the issue date
– Approvals currently in process will follow interim guidance
except the MIL-STD 882 assessment will follow new manual
guidance
– Approval extensions are TBD
19
 Goal
– Characterize the safety hazards and risks associated
with integration and use of lithium batteries aboard
Navy platforms
– Determine if use of platform features (fire fighting,
special stowage, charging capabilities) mitigates risks
associated with batteries and identify unmitigated risks
 Scope
– “Includes all lithium batteries used, carried, or
intended for use or carrying on Navy platforms, both
as standalone batteries and as systems incorporating
lithium batteries. Specifically included are manned
Deep Submergence Systems (DSS).”
– Scope as written does not have universal acceptance
at top levels in NAVSEA
20
 Initial Data Submission
– Top Level Requirements (TLR) List
– Operational Requirements Document (ORD)
– Preliminary Hazard List (PHL)
– Concept of Operations (CONOPS)
 Secondary Data Review due prior to PDR
– Program Management Plan
– Memorandum of Agreement with SEA05, battery tech agent and
program stake-holders
– Hazard Log
– Preliminary Hazard Analysis (PHA)
– Failure Modes and Effects Analysis (FMEA)
 Approved Documentation to Proceed to FDR/Fleet Release
– Battery Test Plan
– Test Report
– Safety Hazard Analysis (Final)
– Manufacturing Audit Report
Note: For projects that are not formal acquisition projects SEA05 will accept equivalent documents.
For instance if there is not a formal TLR list or ORD, alternative formats would be accepted.
21
 Require extensive customization of testing with in-
depth input & direction from SEA-05Z, SEA-05P,
and other cognizant platform warrants
NOTE: This is an all inclusive matrix and many test can be combined into one test by proper design
22
 Contain severe casualty output and limit consequences to
personnel & platform
– Target mitigations to Maximum Credible Event (MCE)
– Review data from Worst Case Event (WCE) as part of the risk analysis
 Proven battery management systems
– Demonstrate reliability & redundancy or inherent fault tolerance
– In some cases (platform dependent) software validation IAW Fly-bywire criteria is mandatory and will be conducted by joint review
 Automated and validated warning systems
– Industrial standard systems preferred to those with limited access
(proprietary)
– Software validation may apply
 Fire suppression and ventilation tactics and systems that are
compatible with the platform capabilities & personnel
– Focused on MCE level as demonstrated by test or simulation
– Based on system and host platform safety precepts for operability
23
 Within the group known as lithium batteries, there are a wide variety of
specific performance and safety characteristics
 Specific lithium battery hazards depend on both battery and system-
related variables
 The major classes of hazards associated with most lithium batteries
include
–
–
–
Venting of noxious and/or hazardous gases
Fire
High pressure events
 When fighting a lithium battery fire, cooling (water) is key and
smothering (heavy gas or chemical blanket) is not generally effective,
therefore Navy safety guidance recommends the use of water or AFFF
as the extinguishing media for lithium battery fires
 The Navy’s Lithium Battery Safety Program strives to minimize risk to
personnel and platforms while allowing the use of lithium batteries on
our ships, aircraft and submarines to advance our military capabilities
through the approval process managed by NOSSA
3/15/11
NSWC Carderock Code 616
24
 Who U Gonna Call?
– Julie Banner
– NSWC Carderock, Code 616
– [email protected]
– (301) 227-1853 desk/voicemail
– (240) 751-7862
– (301) 227-5457 fax
– (240) 597-1394 alternate fax
3/15/11
NSWC Carderock Code 616
25