Battery Energy Storage Systems (BESS) are fast becoming the backbone of our evolving energy landscape. However, the process of commissioning these systems to get them online is often fraught with challenges, including delays, performance inefficiencies, and outright technical failures. These early-stage issues eat into profits, amplify risk, and, if not caught early, can shorten the revenue-earning lifetime of the entire system. A data-driven approach to early identification and resolution of these problems can help transform the commissioning process, ensuring optimal performance right from day zero.
The Challenges of BESS Commissioning
Costly Delays During Commissioning
Across the UK, 37% of BESS projects fail to meet their planned commissioning timelines—some by nearly a year. In ERCOT, delays average 6 to 9 months, triggering a barrage of financial consequences: revenue losses from missed energy trading opportunities, potential fines for grid noncompliance, and the added expense of troubleshooting underperformance. These issues aren’t isolated to any one system, and they’re not uncommon globally, signifying deeper cracks in the commissioning process itself. To ensure smoother energy storage system rollouts in the future, we must take a data-driven approach to identify and address the root causes of commissioning problems.
Misaligned Incentives Among Stakeholders
The commissioning process often exposes conflicting priorities among the various teams involved. Equipment manufacturers and system integrators may not always share full visibility into system issues, focusing instead on equipment delivery. Similarly, engineering and construction teams might prioritize quickly finalizing installations rather than optimizing long-term performance. Such misalignments create challenges for operators trying to establish reliable, transparent, and efficient energy systems in the long term. And, when the Commercial Operations Date (COD) is delayed, significant penalties apply, putting a dent in project ROI before a single kilowatt-hour is sold.
The Reality of Early Failures
The “bathtub curve” is a helpful concept in understanding technology failures in BESS commissioning. The curve illustrates that failures are most likely during the early phase of technology deployment, such as during commissioning. Systems often encounter a surge of issues when first coming online, from calibration challenges to systemic inefficiencies. Collecting accurate data during this early stage is critical for long-term success.
Fig. 1: High failure rate at early life
The Role of Data Analytics in Overcoming Challenges
Independent data analytics have emerged as a powerful solution to tackle these commissioning hurdles. By providing a transparent,unbiased view of system performance, data analytics uncover hidden problemsbefore they escalate, leading to faster commissioning timelines,optimized performance, and reduced operational risks.
Enhanced System Transparency
One of the most significant benefits of data analytics is the clarity it brings. Operators gain full visibility into performance issues, enabling better collaboration with all stakeholders. Problems like imbalances, capacity shortfalls, and equipment malfunctions can be detected early and addressed with targeted solutions, fostering alignment between project teams.
Accelerating Testing and Calibration
Analytics enhance the accuracy and efficiency of Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT), providing insights that help recalibrate systems underperforming during initial tests. These enhancements empower operators to ensure the system achieves peak performance more quickly, reducing delays and setting the foundation for optimal operation.
Real-World Applications of Data Analytics
The practical applications of data analytics in BESS commissioning have led to significant benefits in real-world scenarios. By addressing specific technical challenges, analytics have resolved critical system issues, shortened timelines, and saved substantial costs.
Uncovering and Resolving Performance Issues
One example highlighted by a hybrid BESS facility with over100 megawatt-hours of capacity. During its commissioning, only 88% of the system was operational, while 3% had completely failed, and 9% was experiencing downtime. These performance shortfalls were causing severe financial losses in a rapidly shifting market. By using independent analytics, operators identified the root causes of these problems, including underperforming modules. Targeted recalibrations brought 25 additional battery racks online, cutting months of delays down to weeks and enabling the system to pass mandatory performance tests.
Addressing Technical Failures
- Faulty Cells Across a Production Batch
Long serial connections of battery cells can be particularly vulnerable to discrepancies, as the lowest-performing cell sets the limit for an entire string. Through data analytics, one project discovered internal resistance variations of over 30% caused by inconsistent production batches. After accurately diagnosing the issue, the EPC incorporated additional containers worth more than $5 million to meet the specified capacity and power requirements.
- Balancing Cell Connections
Imbalances often occur in lithium iron phosphate (LFP) systems due to factors like inconsistent self-discharge rates or loose cell connection screws. Analytics identified higher resistance caused by loose screws in one project, which was initially overlooked by onsite teams. After confirming the findings and tightening the screws, operators were able to recover previously lost capacity, underscoring the value of attention to detail. - Detecting Sensor and Electronic Issues
Faulty components, such as defective sensors, can lead to operational shutdowns or safety risks. For example, one system experienced deep discharge events and undervoltage errors caused by defective sensors and parasitic loads. Data analytics pinpointed the failing components, enabling replacement before further damage occurred. This intervention safeguarded the system both energetically and financially, while also mitigating potential safety risks.
Optimizing the Path to Success
Independent data analytics bring tangible benefits to the BESS commissioning process by revealing hidden issues, reducing costs, and accelerating time to operation. With detailed insights gained during early assessments, these tools help lay the groundwork for efficient and reliable long-term energy storage solutions.
The Future of Data-Driven BESS Performance
Renewable energy systems and battery storage are set to play a central role in the global energy transition. By leveraging data analytics during commissioning, operators can unlock the full value of their systems, from improved system health to quicker returns on investment. Whether handling complex technical failures or aligning project teams toward shared goals, data analytics set a new standard for efficiency, transparency, and optimization in BESS deployment.
By taking a proactive and data-driven approach, BESS stakeholders can ensure that their systems are not only operational but also optimized to serve as a foundation for the sustainable energy future.
