Genius-Star-Xi

Improperly secured lithium-ion battery cargo triggered two fires aboard the 'Genius Star XI', actually sailing as 'World Luna', during heavy weather during its transit across the North Pacific Ocean on Dec 24, 2023, an investigation of the National Transport Safety Board, which was published on Dec 18, 2025 found out. The incident highlighted growing concerns about the transport of large-scale lithium-ion battery systems by sea. The vessel was carrying 192 lithium-ion battery energy storage system (BESS) units when lashing belt failures allowed 41 units to shift in heavy seas, causing internal structural damage that led batteries in three units to enter thermal runaway, an uncontrollable heating process that can exceed 572°F. The investigation revealed a critical equipment incompatibility that compromised the entire securing system. The diameter of the D-ring and the inner diameter of the hook (throat opening) were not compatible. The D-ring circumference was larger than the throat of the hook; essentially, the hook was not able to fully seat on the D-ring. This design flaw concentrated securing loads at the bend of the hook rather than distributing them across the full throat, causing the hooks to fracture and separate under stress. The vessel encountered gale-force northwest winds of approximately 26 knots with gusts above 30 knots and combined seas and swells reaching 19 feet near the Bering Sea. On Dec 25, the crew discovered that all BESS units in bay 4 of hold no. 2 had shifted, and black smoke was emerging from cargo hold no. 1. The master ordered the crew to activate the vessel’s fixed carbon dioxide fire-extinguishing system, deploying all 153 CO2 cylinders into cargo hold no. 1. With no remaining CO2 aboard to fight another fire, the vessel diverted to Dutch Harbor. Three days later, while still en route, a second fire erupted in cargo hold no. 2. Without CO2 available, the crew fought the blaze by spraying seawater on the exterior of the hold for approximately four hours. The 'Genius Star XI' arrived at Dutch Harbor on Dec 29, where the Coast Guard directed it to an anchorage two miles from the shore due to reflash risks. No injuries or pollution were reported. The investigation determined that when internal shelves weighing 300 pounds detached from deformed rails and collapsed, they enabled lithium-ion battery packs to move freely and impact the interior structure of the units. Arcing and scorch marks were found within those same 13 units, which likely occurred when the exposed battery pack busbar impacted the inside of the unit and caused the batteries to short circuit. The investigators emphasized critical lessons for the maritime industry in securing large stationary lithium-ion battery units. Crews must follow the vessel’s cargo securing manual and approved lashing plan, thoroughly inspect all cargo-securing arrangements during and after loading, and pay close attention to verify that lashing belt hooks, wires, and chain falls are properly seated on D-rings and attachment points. The vessel, owned by the GS Navigation S.A. and operated by the Taiwan-based Wisdom Marine International Inc., had sailed from Busan on Dec 18 enroute to Long Beach. After the fire, the delivery port was changed to San Diego, where the vessel arrived on Feb 24, 2024, after the damaged cargo was secured and the CO2 system replenished at Dutch Harbor. The fire resulted in damages of $3.8 million. Full report: https://www.ntsb.gov/investigations/Pages/DCA24FM013.aspx

The 'Genius Star XI' departed Dutch Harbor on Feb 11 en route to its intended destination in San Diego, California, with an ETA as of Feb 24. The Unified Command managing the incident has stood down and all response operations have been completed. The vessel continued its voyage after it secured all cargo and completed a Coast Guard Port State Control inspection. The Unified Command had been established with the Coast Guard Captain of the Port as Federal On-Scene Coordinator, Alaska Department of Environmental Conservation as State On-Scene Coordinator, and Gallager Marine Systems as Incident Commander. Report with photo: https://www.news.uscg.mil/Press-Releases/Article/3674725/mv-genius-star-xi-departs-dutch-harbor-alaska-concluding-response-operations/

The 'Genius Star XI' berthed in Dutch Harbour to streamline logistics and provide a safer environment necessary for the timely completion of ongoing work on Jan 30. The vessel moved to the dock based on recommendations from the salvage master, the Coastguard salvage engineering response team, and other technical experts with knowledge and experience on how best to re-secure the cargo. The duration of the vessel dockside will depend on port operations and competing needs for the dock space. The 'Genius Star XI' was relocated to the Unalaska Marine Centre Docks 1 and 2, where responders will work to resecure the lithium-ion industrial battery unit cargo that was damaged at the end of December 2023. The vessel's crane wast to be used to load supplies to resecure damaged and dislocated cargo. There was no plan to land any cargo from the vessel shoreside in Dutch Harbour. Prior to entering port, the community air monitoring system was repositioned as directed by the Coastguard Pacific Strike Team and local public safety officials. There have been no reports of abnormal air quality on the vessel or in the community since the start of the incident. The CO2 bottles for the vessel's onboard firefighting system are being replenished, a requirement for the vessel to eventually continue its voyage beyond Dutch Harbour. An investigation into the cause of the fire was ongoing.

The Salvage Marine Firefighting team began implementing the air circulation plan approved by the Unified Command in the afternoon of Jan 5. The purpose of the operation was to increase air flow in the cargo holds of the 'Genius Star XI'. The Unified Command’s Technical Expert Advisory Group developed an air circulation plan for the cargo holds and response personnel are executing the first step of that plan while continuously conducting air monitoring onsite and ashore. Air quality remained normal on the vessel and in the community of Unalaska. Teams will continuously conduct air monitoring as outside air is slowly circulated through the cargo holds.  Response personnel successfully offloaded all empty CO2 bottles for refill and reinstallation. The refilled bottles will be reloaded onto the vessel as part of the fire suppression system required by the International Maritime Organization’s Safety of Life at Sea requirements. The Technical Expert Advisory Group was in the process of developing recommendations for opening the cargo hatches and conducting visual inspections once the air circulation process is completed. Additional technical experts were enroute to evaluate options for entry into the cargo holds for further inspections. The Unified Command, consisting of the Coast Guard Captain of the Port, Gallagher Marine Systems, and the Alaska Department of Environmental Conservation, continued to work closely to coordinate response efforts on this incident. A one-mile safety zone around the vessel remained in place. Mariners who wish to enter that zone shall request permission on VHF Channel 16.