Building safer, smarter BESS projects: How to manage risk from factory to field
7 min read
As battery energy storage systems (BESS) scale globally to support the clean energy transition, the spotlight is increasingly shifting toward quality, safety, and resilience. Much like the evolution of the PV industry, where quality control became a defining factor for project bankability, the same is now true for BESS.
But here’s the catch: battery storage is more complex — involving chemistry, electronics, software, and logistics. And that complexity makes robust QAQC (Quality Assurance and Quality Control) and supply chain risk mitigation absolutely essential, from procurement to commissioning.
In this blog, we outline how developers, investors, and integrators can take a proactive approach to managing BESS supply chain and manufacturing risks, safeguarding both project outcomes and long-term sustainability.
The global BESS market is growing rapidly, with demand driven by the need for flexible grid support, renewable integration, and clean backup power. But this expansion brings challenges:
To navigate this complexity, project developers must look beyond just technical specs and cost per kWh. They need a risk-based supplier evaluation framework — one that considers origin, ethics, and operational reliability.
Building quality into your BESS project starts long before the battery is delivered. A strong QAQC framework includes:
Project Phase
QAQC Action
Pre-contract
Define safety and performance standards (IEC, UL, ISO) in contracts
Pre-production
Perform factory audits of cell and system suppliers
During production
Implement inline production monitoring (IPM) for key components
Pre-shipment
Witness Factory Acceptance Tests (FAT) to confirm performance
Post-shipment
Conduct on-site inspections and supervise commissioning
At each stage, independent inspection and documentation are key. And while system-level testing is becoming more common, access to battery cell manufacturing lines remains a major gap, often due to IP protection and limited supplier transparency.
Data from 11 global manufacturers (2024) shows that nearly 50% of all BESS issues originate at the battery cell level — often due to:
Poor warehouse/storage conditions
Non-compliance with SOPs
Incomplete incoming quality checks
Missing certifications/documentation
These findings are concerning, given that cell-level defects can lead to thermal events, performance losses, or warranty voiding. The lesson: QAQC must go deep, even when access is difficult.
Just as the solar industry matured through standardisation and third-party inspection, the battery storage sector must now do the same. And while access challenges remain — especially at the cell level — the cost of not acting is far greater: failed systems, fire risk, lost revenue, and reputational damage.
The path forward is clear: early and continuous QAQC, proactive risk mitigation, and a shift from price-driven to performance- and ethics-driven procurement.
Only then can BESS truly deliver on its promise: to power a safe, sustainable, and reliable energy future.
At Re-Twin Energy, we help storage developers, investors, and EPCs derisk projects from the ground up — with digital twin technology, supplier scoring, and data-driven QAQC support. Discover how we help ensure quality, safety, and bankability from cell to site at re-twin.energy.
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