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If a data-center battery system is abnormally hot, smoking, hissing, popping, venting gas, or burning, treat it as an active emergency. Warn people nearby, move away using the facility’s emergency plan, notify the site emergency lead and fire service, and keep everyone out until responders authorize access. Do not open the enclosure, approach a vent, improvise firefighting, or operate a generic disconnect.
The correct shutdown, isolation, exclusion distance, ventilation setting, and suppression method depend on the installed chemistry, UPS or energy-storage model, manufacturer instructions, facility plan, and local authority. This guidance is principally about lithium-ion systems; data-center batteries also use other chemistries and designs.
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What to do in the first minutes
Use the site emergency action plan rather than trying to diagnose the battery yourself. OSHA says that plan should contain lithium-ion incident procedures based on manufacturer instructions and NFPA guidance, and that workers should be trained on them. The following sequence is appropriate for general staff unless your written plan assigns a different, more specific action.
- Recognize the event. A rapid temperature rise, smoke, flame, gas or vapor venting, bulging, cracking, popping, hissing, or physical damage is a danger sign. An alarm or hot spot can precede visible fire.
- Warn people and move away. Tell others to leave the area and follow the facility’s evacuation or shelter instructions. Do not walk toward the equipment to read a label, silence an alarm, retrieve belongings, or confirm what failed.
- Raise the alarm. Contact the site emergency lead or control room through the designated channel and call the fire service according to the emergency plan. Report the room, rack or enclosure identification if it can be obtained remotely and safely.
- Keep clear of smoke and venting. Do not enter a smoky room or stand near a relief opening. Smoke can contain toxic gases and fine particulates even when no flame is visible.
- Provide information without approaching. From a safe location, give responders the known battery chemistry, manufacturer, model, alarm messages, location, and facility drawings or emergency documents. A trained person can retrieve records electronically or from a staging point; nobody should approach a damaged enclosure to collect them.
- Wait for authorization. Re-entry, equipment access, ventilation changes, and any electrical work belong to the fire service and qualified, authorized facility personnel following the documented procedure.
Do not assume that a falling temperature, a cleared alarm, or a quiet enclosure means the incident is contained. A lithium-ion battery can remain energized and can reignite after apparent extinguishment.
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Warning signs and what they mean
These observations indicate a potentially escalating failure, not a reliable diagnosis of its stage:
- Temperature rising faster than normal or a high-temperature alarm.
- Smoke, visible flame, sparks, or a chemical odor.
- Hissing, popping, cracking, or a sound of pressure venting.
- Bulging, swelling, cracked cases, leaking material, or other mechanical damage.
- Gas, vapor, or white/gray clouds emerging from a module, rack, cabinet, or pressure-relief path.
- Evidence of impact, flooding, overheating from nearby equipment, or an abnormal charging event.
USFA identifies rising temperature, bulging, mechanical damage, popping or hissing, and visible gas venting as signs associated with lithium-ion damage or thermal runaway. Any one of them warrants the emergency response in your plan; waiting for a flame can expose people to a more severe event.
Why an overheating battery can become a major hazard
OSHA describes thermal runaway as a chain reaction: heat released by one failed cell damages neighboring cells, which then release more heat. Internal short circuits, mechanical damage, excessive temperature exposure, and improper charging can initiate the process. In a large UPS or stationary energy-storage system, many cells and modules can supply energy after upstream power is removed.
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| Hazard | Why it matters during an incident |
|---|---|
| Fire | Heat can spread from a failed cell to adjacent cells and materials. |
| Explosion or pressure event | Vented gases can ignite or accumulate in an enclosure or room. |
| Stored electrical energy | Disconnecting incoming power does not necessarily remove energy in cells, capacitors, or other equipment. |
| Toxic exposure | OSHA lists possible byproducts including hydrogen fluoride, hydrogen chloride, hydrogen cyanide, phosphoryl fluoride, carbon monoxide, carbon dioxide, black carbon, and other particulates. The actual gases and concentrations vary by system and event. |
| Reignition | Cells that appear extinguished can heat again, requiring continued assessment and monitoring. |
Because the composition and concentration of gases are not predictable from a label or smell, ordinary workplace PPE does not make an untrained entry safe. Hazard assessment, respiratory protection, electrical controls, and emergency training must be established in advance.
Separate responsibilities by role
| Person | Safe responsibility during the event | What is outside that role |
|---|---|---|
| General employee, contractor, or visitor | Raise the alarm, leave by the planned route, warn others, call the designated emergency number, and wait at the assembly or safe location. | Do not open doors or cabinets, investigate smoke, reset alarms, operate disconnects, fight the fire, or return for equipment. |
| Control-room or security staff | Activate the site notification process, provide remote alarm information, meet responders from a safe location, and control access. | Do not enter to verify a sensor, change ventilation, or silence an alarm unless the written plan specifically assigns that action and conditions are safe. |
| Qualified, authorized facility personnel | Coordinate with the incident commander and fire service, use the exact manufacturer and site procedure, and document equipment status. | Do not improvise a shutdown sequence, bypass interlocks, open a hot enclosure, or assume an upstream breaker has de-energized the battery. |
The distinction is important: authorization and training are system-specific. A person who is qualified to work on one UPS or battery technology may not be qualified for another.
Shutdown and isolation: why there is no universal button
Whether a UPS or battery system should be shut down, isolated, or left energized during an emergency depends on the equipment, region, emergency plan, and responder direction. Mitsubishi Electric notes that requirements differ by location and equipment and that local authorities determine applicable codes. Its UPS-specific controls cannot be generalized to other installations.
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For trained personnel, use the documented sequence for the exact model and coordinate every step with responders. The procedure may identify upstream and downstream breakers, battery disconnects, emergency-stop controls, remote monitoring, and verification points. It should also state which loads must remain powered, who has authority to operate each control, and how to prevent automatic restart.
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Smoke, flame, or a venting enclosure
Move upwind or to the location specified by the facility plan, if that can be done without passing through smoke. Keep doors and barriers closed only when the plan and responders direct it; do not improvise by sealing or opening a room. Ventilation and exhaust controls are engineered features whose operation can affect fire and gas movement.
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Do not select an extinguisher, suppression agent, hose stream, or water application from a generic article. The right tactic depends on the battery, enclosure, energized state, fire conditions, and fire-service procedures. For its own products, LG Energy Solution warns: "If a high-temperature event occurs in the battery enclosure, do not open the enclosure door, as it may explode." That instruction applies to the covered LG product context, not every battery system. The same guide says decisions about applying water to the exterior should be made with LG representatives.
Firefighters may need to establish a larger exclusion area than the facility normally uses, monitor temperatures, control gas hazards, or allow a system to cool for an extended period. Follow their commands rather than treating a visible reduction in smoke as permission to approach.
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After the fire appears to be out
USFA warns that lithium-ion batteries can reignite. Responders may use thermal imaging, gas monitoring, water or other tactics, and extended observation to determine whether cells remain unstable. The site should not reset alarms, remove modules, restart a UPS, or return the room to service until the incident commander and the responsible qualified authority release it.
Post-incident handling can expose workers to damaged cells, contaminated water, sharp metal, and energized conductors. Preserve the scene as required, record alarm histories and actions, and arrange removal, transport, and disposal through the manufacturer or an authorized hazardous-material process. Do not place a damaged module in a normal waste stream or transport it in a personal vehicle.
Build a battery-specific emergency plan before an event
A useful plan turns general warnings into decisions that a particular site can execute. At minimum, document:
- The chemistry, manufacturer, model, capacity, cabinet or rack locations, and one-line electrical drawings.
- Alarm thresholds, monitoring contacts, remote shutdown capabilities, and the conditions that require evacuation or notification.
- Who may operate each disconnect or emergency-stop control, and the verification method for stored energy.
- Fire-service access routes, building hazards, staging areas, gas or smoke control information, and after-hours contacts.
- Manufacturer emergency numbers, current manuals, safety data, and the revision date of the procedure.
- Training, drills, respiratory and electrical-rescue provisions, and a process for updating the plan after equipment changes.
OSHA’s lithium-ion control guidance calls for emergency action procedures based on manufacturer instructions and NFPA guidance, along with worker training. A plan that names only “UPS failure” is not enough; it should address overheating, venting, fire, explosion, electrical isolation, evacuation, responder handoff, and re-entry.
Standards and local authority
OSHA says there is no single OSHA standard devoted exclusively to lithium-ion batteries. Depending on the work and jurisdiction, requirements can involve emergency action plans, fire prevention, personal protective equipment, respiratory protection, hazardous-material response, electrical safety, and lockout/tagout. OSHA’s standards overview is available at https://www.osha.gov/lithium-ion-battery-safety/standards.
NFPA 855 is the standard for installation of stationary energy-storage systems. The 2023 edition addresses subjects including fire detection and suppression, explosion control, exhaust ventilation, gas detection, and thermal runaway. The edition adopted by your jurisdiction and the requirements enforced by the authority having jurisdiction control what applies at a particular facility. Consult the current code official and fire service rather than relying on an out-of-date edition.
Why preparation matters: a documented case
NFPA’s Energy Storage Systems Safety Fact Sheet describes a 2019 event at the McMicken Battery Energy Storage System in Surprise, Arizona. A 2.16 MWh lithium-ion system experienced thermal runaway followed by an explosion, seriously injuring a fire captain, fire engineer, and two firefighters. The case illustrates why responders need system information, exclusion controls, and a plan for stored energy; it is not a measure of the frequency of battery incidents.
Quick Recap
Reliable references for the emergency plan
- OSHA: Lithium-ion Battery Safety — Hazards
- OSHA: Lithium-ion Battery Safety — Control
- U.S. Fire Administration: Risks and response strategies for lithium-ion battery fires
- NFPA: Energy Storage Systems Safety Fact Sheet
- LG Energy Solution: Safety Guide
- NFPA 855, 2023 edition
- Mitsubishi Electric: Lithium-Ion UPS FAQs
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