Introduction

As Battery Energy Storage Systems (BESS) become central to the global energy transition, safety and environmental concerns take center stage – especially during thermal runaway incidents. These events can release a complex mix of toxic gases and particulates into the air. This is where plume modelling, particularly using AERMOD, becomes critical for proactive risk assessment and response planning.

The BESS Failure Risk: What Are We Dealing With?

In the event of a fire or thermal incident, BESS units can emit:

• Hydrogen Fluoride (HF)
• Carbon Monoxide (CO)
• Hydrogen Chloride (HCl)
• Volatile Organic Compounds (VOCs)
• Fine and coarse particulate matter (PM2.5, PM10)
• High-temperature smoke plumes that rise and spread unpredictably

These emissions pose serious health risks to first responders, nearby communities, and workers.

Why Plume Modelling Is Non-Negotiable

Effective plume analysis helps:

• Quantify toxic emissions during thermal events
• Model pollutant dispersion using atmospheric and source data
• Predict exposure risks at site boundaries and public zones
• Design emergency response strategies, including evacuation and shelter-in-place
• Ensure compliance with air quality standards (e.g., NAAQS, HAPs)
• Inform ventilation and safety design in enclosed or urban settings
• Enhance public and stakeholder trust through transparent modelling data

The Plume Analysis Workflow

1. Desktop Study & Data Review

• Meteorological data (1–5 years)
• Spill history, land use, thermal events
• Fire suppressant use (e.g., PFAS foams)

2. Hazard & Source Term Definition

• Data from UL 9540A or OEMs
• Emission rates, gas types
• Temperature, release height, exit velocity

3. Air Dispersion Modelling

• Tools used: AERMOD, PHAST, SAFETI
• Simulations for multiple weather and seasonal conditions

4. Receptor Grid & Impact Analysis

• Ground-level concentration measured at:
  • Site boundaries
  • Public access points
  • Sensitive receptors (schools, hospitals)

5. Recommendations

• Optimized ventilation layouts
• Emergency protocols and signage
• Community alert systems
• Compliance documentation for EIAs and permits

Looking Forward: AERMOD as a Safety Standard

As energy storage projects scale globally, plume modelling must become a standard practice. From design validation to emergency preparedness, tools like AERMOD ensure that clean energy adoption doesn’t compromise on human or environmental safety.

Need Plume Analysis Support?

Our Environmental Engineering team offers turnkey plume modelling services for BESS, industrial facilities, and solar-hybrid projects.

Get in touch to integrate safety at the design stage.

Colombo, Sri Lanka – Marking a pivotal moment in South Asia’s renewable energy journey, SgurrEnergy has secured a ground-breaking contract for Sri Lanka’s first 100MW Solar PV project integrated with a 12MWh Battery Energy Storage System (BESS). This first-of-its-kind initiative sets a new benchmark in the island nation’s energy sector and reinforces SgurrEnergy’s leadership in delivering transformative, future-ready renewable energy solutions.

The multi-phase project scope includes:

• PV + BESS Optimization: Advanced modelling, simulation, and LCoE/LCoS analysis
• Hydrology Studies: Comprehensive water resource evaluations
• Procurement Assistance: Preparation of RfPs and bid evaluations
• Engineering Support: Basic to detailed engineering up to 33kV, QA, fire safety, and system design
• Project Documentation & Quality Assurance: Acceptance reports and optional PV module inspections

The deployment will feature advanced bi-facial/mono PERC modules, string inverters, and fixed tilt or HSAT technologies – driving long-term performance and grid resilience.

“We’re proud to partner on this landmark project, contributing technical depth and strategic insight to support Sri Lanka’s clean energy ambitions,” said Arif Aga, Director, SgurrEnergy.

With this milestone, SgurrEnergy continues its mission of enabling global clean energy transitions through deep expertise, smart engineering, and uncompromised quality.

We are in News: ManufacturingToday | PowerLine | EVvolution Auto India

When environmental, social, and geopolitical risks converge—only strategy-led insight can ensure execution without compromise.

At SgurrEnergy, our Environmental and Social Impact Assessment (ESIA) for a 300MWAC Solar PV Project in Karbala, Iraq, wasn’t just a regulatory checkbox—it became a strategic lever to de-risk development, unlock stakeholder confidence, and future-proof energy infrastructure in a high-stakes setting.

From day one, the project demanded a comprehensive view—ecological proximity to the Al Razzaza Protected Area, active security threats, hydrological vulnerabilities, and evolving climatic pressures presented a complex canvas. SgurrEnergy’s multi-disciplinary team of environmental engineers, biodiversity experts, chemists, social scientists, and GIS specialists collaborated on-ground and remotely to extract actionable intelligence from every variable.

Sustainability in Desert Terrain

Our baseline climate models accounted for SSP 2-4.5 and SSP 5-8.5 scenarios—ensuring long-term resiliency in a rapidly evolving desert climate. With corrosive soil close to a saline lake, we established the corrosion category using ISO 9223/9224 standards, directly influencing structural design with recommended coating thicknesses for critical PV components.

Biodiversity-First Engineering

Spotting deceased fishes along the Al Razzaza Lake shoreline triggered a deeper biodiversity review. Using IFC PS6 and IBAT frameworks, we identified high salinity and industrial pollution as stressors, crafting a mitigation plan inclusive of habitat protection, water conservation awareness for labour, and greenbelt restoration.

Crucially, protection measures were integrated for species like the Leopard Barbell Fish and migratory birds such as the Sociable Lapwing—right down to tower spacing adjustments and anti-collision diverters.

Engineering Through Instability

Amidst region-specific security concerns, SgurrEnergy implemented a proactive Security Management Plan aligned with IFC PS4, including perimeter zoning, secure staff transport, and coordinated stakeholder engagement. Despite local agencies being hesitant, we executed full-site monitoring with imported instruments and international-level safety protocols.

Stakeholder consultations extended to Ministry officers, army personnel, and community labourers, reinforcing trust and refining local context into our risk frameworks.

Defending Energy Yield Against Adjacent Risk

When news of a planned waste treatment plant emerged just west of the solar boundary, we conducted dispersion modelling for pollutants and shading analysis. Recommendations included a minimum 2km buffer and elevation-based distance planning to protect panel efficiency and air quality—ensuring uninterrupted yield and reduced O&M complexity.

The Strategic Edge

By embedding long-range ecological, social, and operational risk mitigation from the start, this ESIA didn’t just greenlight a project—it elevated its credibility. SgurrEnergy’s insight-driven model empowered stakeholders to make bold, future-ready decisions while preserving biodiversity, ensuring local security, and aligning with global ESG expectations. 

Pune, India, February 2025: A structured, data-driven, and technologically advanced pre-bid services ensures success of renewable energy approach ensure the success of renewable energy projects, according to Mr Arif Aga, Director of SgurrEnergy. 

SgurrEnergy is setting new benchmarks in optimizing renewable energy bids through a structured, data-driven, and technologically advanced approach. With its technical excellence and 360-degree service approach, the company has been transforming pre-bid service landscape. The company has been redefining the pre-bid service landscape with its technical prowess and 360-degree service approach. It has experience with more than 125 GW of projects across the globe.

“Precision and deep technical expertise are the keys for success and our approach is rooted in these areas. It is very critical to systematically analyze tender specifications and here we leverage our extensive experience. We have been helping our clients navigate complexities of pre-bidding process and optimize their proposals for maximum efficiency and competitiveness,” said Mr Arif Aga.

It is widely admitted by seasoned consultants that pre-bid services is a rigorous technical tender review that ensure every bid is strategically positioned for success. “Our multidisciplinary team of experts meticulously examines tender documents, identifying key requirements, challenges, and optimization opportunities. This exercise gives us an edge as a detailed evaluation covers critical aspects such as tender review, boundary encoding, and manufacturer analysis. By covering these critical aspects, we enable our clients to mitigate potential risks and align with long-term project goals,” added the Director of Sgurr Energy- a global leader in renewable energy consulting.

The company believes that integrates advanced scientific modelling and simulation tools to refine engineering solutions work as great enablers and help clients to submit competitive and technically superior bids. The company’s proprietary modelling techniques enhance accuracy by conducting multi-scenario simulations, refining battery sizing, and optimizing DC-to-AC capacity ratios to maximize energy yield. Sensitivity assessments also serve as a reference for system design, guaranteeing a balance between long-term operational efficiency and capital investment.

In addition to technical evaluation, thorough site investigations are essential for informing engineering methods that comply with regional environmental and regulatory requirements. According to Mr Aga, these studies include topographical and geotechnical assessments for foundation design and infrastructure layout, hydrology and flood risk analysis to mitigate water flow risks, and irradiance potential evaluations to determine the most suitable locations for energy generation.

In order to ensure technical soundness from conception to implementation, the renewable energy consultancy giant’s power system studies also use industry-standard tools like PSCAD, DIgSILENT, and ETAP to model power flow and grid stability. “We believe that a successful bid is not just about cost but also about reliability and sustainability. By combining scientific precision with industry-leading expertise, we provide our clients with data-backed insights that drive down costs, reduce risks, and enhance overall project viability,” added Mr. Aga.

A holistic approach is needed to pre-bid services that can deliver measurable value at every stage of project development. Cost-effective engineering, comprehensive risk mitigation plans, expedited project schedules, and adherence to international quality standards all benefit clients.

Innovation and technological prowess are essential for the renewable energy industry’s continued growth. “Our goal has been to provide investors, EPC contractors, and developers with the knowledge and tools they need to succeed in the long run. By assisting our clients in creating more intelligent, effective, and financially feasible projects, we firmly believe in influencing the direction of renewable energy,” concluded Mr. Aga.

About SgurrEnergy

Founded in 2002, SgurrEnergy is a leading renewable energy consultancy, specializing in solar, wind, and hybrid energy solutions. With a team of over 185 engineers and experts, the company has delivered more than 1,000 projects across 40+ countries, consistently delivering best-in-class technical advisory, engineering, and project management services.

Know more about our services : Inspection Services | Energy Advisory | Design & Engineering | Project Management

As the global renewable energy industry accelerates project timelines are tightening and technology complexity is increasing. In this environment, comprehensive inspection services are no longer optional – they are a strategic imperative for ensuring quality, minimizing risk, and meeting ambitious climate targets.

The Complexity of Large-Scale Renewable Energy Projects

As renewable energy projects grow in scale and complexity, they present unique challenges. Large projects often involve multiple stakeholders, tight schedules, and the integration of new technologies. In these environments, ensuring the quality and performance of every component—from production to transportation to installation – is vital. However, the speed at which these projects need to progress often leaves little room for error. This is where comprehensive inspection services play a crucial role.

SCOPE

• In-Process Inspection
• Pre-Dispatch Inspection (PSI)
• Container Loading Inspection (CLI)
• Laboratory Testing Witness

CHALLENGES

1. Schedule Conflict & High Volume Production: Coordinating inspection and reporting under the fast-tracked time scale of manufacturing 450MW within 6 months (approx. 1.5MW/day).
2. Stakeholder Communication Gaps: Ensuring seamless coordination among production teams and technical requirements on inspection procedures due to varied opinions and procedures.
3. Daily Reporting Discipline: Aligning report schedules, walkthroughs, and validations to enable project monitoring and decision-making.
4. Quality Oversight for New Technologies: Qualifying regular quality of new G12 TOPCon modules that have yet to be extensively installed.
5. Deviation in Internal Process Tests: Chances of bypassing or inadequately conducting critical tests such as Hi-pot, EL, or lamination Gel content etc. because of pressure from production.
6. Production and Rejection Data Tracking: Inability to trace line-wise and batch-wise rejection data for early diagnosis and corrective measures in process.
7. Critical PSI Deviations: Non-adherence in critical PSI activities, particularly in IV measurement consistency and sampling discipline.
8. Shop floor Environment Noncompliance: Factors like inadequate lighting, excessive dust, or unsuitable handling procedures impacting module integrity.
9. Untrained Operators: Lack of training for important processes like stringing, lamination, or inspection, resulting in defective modules being cleared undetected.
10. Inadequate Time Allotment for Key Processes: Curing and buffer time between lamination, framing, and packaging not adhered to, compromising product stability.
11. Preventive Maintenance Verification: Infrequent preventive maintenance on stringers, laminators, and simulators, resulting in equipment-based quality problems.

SOLUTION

1. On-Ground Inspection Teams: Utilization of 4 dedicated full-time SgurrEnergy inspectors working across shifts for continuous Inspection services during production.
2. Clear Scope Establishment: Alignment of scope with written inspection flow, PSI lot sizes of 10MWp, well-defined roles, and expectations communicated with client
3. Structured Reporting Mechanism: Standardized daily reporting in the form of PDF-based highlights (Hi-pot, EL, IV) and Excel checklists for in-process checkpoints, with reports within 24 hours.
4. Stakeholder Alignment: Arranged introductions between SgurrEnergy inspectors and client’s production management before team deployment to allow seamless execution from Day 1.
5. Benchmark Compliance Monitoring: Monitoring tolerance levels during reflash (within 1%, +ve only), test integrity, and sharing visual records of inspections in real-time.
6. Proactive Process Corrections: Process inspectors with authority to intervene at process deviations, halting and correcting procedures in real time.
7. Daily Monitoring of Internal Testing: Ongoing verification of EL, IV, Hi-pot, and curing station performance by checking against checklist standards and operator feedback.
8. Rejection Data Monitoring: Gathering and comparing rejection trends daily to suggest real-time improvements and material or machine adjustments.
9. Rapid Operator Training: Impromptu training of line staff at locations where recurrent problems occur, enhancing primary-level quality control.
10. Line Control Parameter Monitoring: Regular monitoring and adjustment of process machine parameters (i.e., stringer solder temp, laminator pressure/vacuum) for process stability.
11. Preventive Maintenance Recording: Periodic check of maintenance records and equipment status to avert equipment-rejection causes and provide process integrity.

IMPACT

1. Proactive Quality Assurance: Timely intervention and constant coverage minimizes rework, defect rates and improves quality.
2. Documentation Standardization: Documents as per the requirement, making it traceable and real-time project decisions.
3. Production Schedule Synchronization: Inspection coordinated with the manufacturing plan allows uninterrupted monitoring and escalation.
4. Transparency Across Stakeholders: Clear update and daily reports along with snapshots and highlights giving full visibility to client.
5. Enhanced A-Grade Yield: Greater percentage of error-free modules through defect checking, prompt correction, better SOP following and training.
6. Process Optimization & Industry Compliance: In-line process audits and PM checks bring production in line with best practices, reducing long-term risk and delays.

At a Glance:

• 450 MW modules inspected over 6 months
• 4 full-time inspectors deployed across shifts
• 100% daily reporting compliance
• >95% A-Grade yield achieved
• >25 SOP deviations resolved in real time

Optimizing Long-Term Success

Inspection services are not just about addressing immediate concerns – they are about creating long-term value. By continuously monitoring key metrics, providing real-time updates, and aligning stakeholders’ goals, inspection services help streamline processes and ensure project stability. Furthermore, regular audits and preventive maintenance checks help identify potential future risks, allowing teams to take corrective action before issues escalate.

The result? A more reliable, cost-effective, and compliant renewable energy project that can stand the test of time.

Read more: SgurrEnergy

At SgurrEnergy, we understand the complexities of large-scale renewable energy projects and the critical role inspections play in ensuring their success.

Discover how our tailored inspection services can streamline your project’s execution, minimize risks, and maximize performance.

Author: Shravan Shanbhog, Senior Engineer – Inspection Service (PV modules)