NTSB: Faulty lashings led to Genius Star XI battery cargo fires

The National Transportation Safety Board (NTSB) has released its report on an incident that began Christmas Day 2023 when the first of two fires broke out in lithium-ion battery energy storage system (BESS) units stowed as cargo aboard the 410-foot bulk cargo vessel Genius Star XI.

Owned by GS Navigation S.A. and operated by Taiwan-based Wisdom Marine, the vessel was transiting the North Pacific Ocean en route to Long Beach, Calif., from Haiphong, Vietnam, where it had loaded a cargo of 92 lithium-ion battery energy storage system (BESS) units (Powin Stack 800 Centipede Energy Segment) and 35 Harmonic Adsorption Recuperative Power System (HARPS) heat exchangers. The BESS units were designed to function as stationary landside power supply units that stored energy during peak electrical generation and could supply power to an electrical grid during low-generation periods.

Investigators determined that improperly secured lashing belts failed, allowing 41 lithium-ion BESS units to shift in the cargo holds, leading to internal structural deformation. This damage caused batteries in three of the units to enter thermal runaway, when a lithium-ion cell enters an uncontrollable, self-heating state that can exceed 572°F, causing the two fires within the holds.

After the first fire, the Genius Star XI crew activated the vessel’s fixed carbon dioxide fire-extinguishing system and diverted to the nearest port, Dutch Harbor, Alaska, for assistance. The fire was extinguished. While en route to Dutch Harbor, a second fire occurred in another cargo hold on December 28. The crew cooled the affected area externally with fire hoses. The fire was confirmed extinguished when the Genius Star XI arrived at Dutch Harbor on Dec. 29. No injuries or pollution were reported.

The fires caused $3.8 million in damages. to the vessel

The vessel had encountered gale-force northwest winds of about 26 knots, with gusts above 30 knots and combined seas and swells reaching 19 feet. These conditions caused significant vessel rolling and seawater to wash over cargo hatches.

NTSB investigators emphasized the importance of ensuring that cargo aboard marine vessels—particularly large stationary lithium-ion BESS units—is properly secured.

Crews should:

• ​Follow the vessel’s cargo securing manual and approved lashing plan.
• Thoroughly inspect all cargo-securing arrangements during and after loading.
• Pay close attention to lashing belt hooks, wires, and chain falls to verify they are properly seated on D-rings and attachment points.
• Proper inspection and verification are critical to preventing cargo movement, structural damage to battery units, and potential thermal runaway events during heavy weather.

Download the full NTSB report HERE

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