By Niranjan Sudhakar (Technical Manager at TÜV SÜD)
What happens when a battery cell fails? At TÜV SÜD, we don’t just ask – we test, measure, and design solutions that set industry benchmarks.
Energy storage systems (ESS) are at the heart of the global transition to renewable energy. But with innovation comes responsibility: thermal runaway and fire propagation in battery systems pose serious safety challenges. At TÜV SÜD, we tackle these challenges head-on through rigorous UL 9540A cell-level testing – work that not only meets standards but helps shape them.
What We Do: UL 9540A Cell-Level Testing
Controlled Abuse Testing
Our engineers perform precise abuse tests on individual battery cells using pressure vessels (20L and 500L). Cells are subjected to failure modes such as overcharge, nail penetration, and spot heating – under both inert (argon) and air atmospheres – to replicate real-world conditions.
Real-Time Data Acquisition
We monitor pressure, temperature, and voltage throughout each test to quantify venting forces and thermal runaway behavior. This data drives safer venting strategies, fire barriers, and module spacing.
Advanced Gas Analysis
When cells fail, gases matter. Using gas chromatographs with flame ionization and thermal conductivity detectors, we identify flammable and toxic compounds (H₂, CO, CH₄, C₂H₆, etc.). We determine critical parameters like Lower Flammability Limit (LFL), explosion pressure, and burning velocity – following ASTM E918, EN 15967, and ISO 817.
Scaling Up
Insights from cell-level tests inform module and system-level evaluations: heat release rates, gas generation, external flaming, and fire protection effectiveness. The goal? Safer installations and guidelines that protect people and assets.
Technical Challenges We Solve
- Moisture & Gas Sampling: We use thermoelectric chillers and coated stainless steel tubes to prevent reactions with acidic gases – ensuring accurate composition analysis.
- Empirical Validation: Experimental flammability data validates predictive models, supporting reliable safety systems and early detection (e.g., gas sensors in ESS).
- Same-Day Analysis: Rapid in-house testing minimizes changes in gas composition, improving accuracy and speed.
Impact and Applications
Our work influences:
- Safer battery designs and venting strategies
- Fire protection system performance
- Installation and ventilation requirements
- Emergency response planning
And it’s not just stationary storage – these methodologies apply to automotive, aviation, and heavy machinery batteries.
Beyond Battery Testing: A World of Opportunities
TÜV SÜD offers far more than battery safety roles. Our engineers work across diverse fields such as:
- Automotive & Traffic Safety: Testing autonomous driving systems and alternative fuels
- Industrial Plants & Energy: Ensuring safety and sustainability in industrial technology and renewable energy projects
- Digital & IT Security: Driving digital transformation and cybersecurity solutions
- Medical Devices & Healthcare: Impacting patient safety through rigorous product testing
- Building Technology & Sustainability: Creating safe, efficient, and sustainable infrastructure
With over 1,000 locations worldwide and nearly 30,000 professionals, you’ll find opportunities to grow in technical, leadership, and cross-functional roles. Our global learning programs, expert communities, and digital platforms ensure continuous development—because at TÜV SÜD, learning never stops.
Ready to join us? Explore career opportunities and learn more about the variety of our jobs here: TÜV SÜD Group Jobs
Sponsored Content by TUV
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