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Existing system retrofit projects

Under the constraint of keeping the existing system in continuous operation,
2.61 MWh amplifier and interface upgrade completed

Item number TC-DEMO-PROJ-RETRO-2610
Type of project / Web-enabled
Capability +2.61 MWh (26 group x 10 amplification units)
Existing systems PCS / EMS / BMS / protection / measure retention and upgrade
Project Status CUTOVER COMPLETE
Commissioning Date 2025-05-14 (night window)
AS-IS (pre-modification/ established system) The original PCS continues to operate with the battery system, while the former EMS and the protection interface continue to assume station-level control.
CUTOVER COMPLETE 2025-05-14
TO-BE (modified/ amplified system) Add new batteries to PCS, upgrade communication, protection, clock synchronization and running calibres.

01 AS-IS asset scanning Pre-reform measurements

Existing PCS (250kW) Run for years, keep using
Original EMS cabinet Main site table and control logic
BCU / BMS Battery management interface measurement
Site protection / measurement Protection and measurement links
Interfaces and cable measurements Communications / Power / Local
Solidware / Configuration List Version and parameter baseline
Alarms and history Run history and known problems
I/O and locks Key Input / Output Status
Existing PCS: Four 250 kW PCS continue to be retained. On-site check of rated parameters, protection settings, control interfaces and solidware versions.

02 TO-BE Structure and scope of adaptation

Existing system (reserved)
Connect Point
35kV bus
New system (enrichment)
PCS
PCS 250kW × 4 Existing PCS / conversion system
BAT
Battery 1.40 MWh Original battery system
EMS
EMS Main Station Control main station
PRO
Protection / Measurement Original site interface
PCS
PCS 250kW × 10 Add Enhanced PCS
BAT
Battery 2.61 MWh Add amplification batteries
BMS
BMS / BCUs Add Battery Management Chain
COM
/ Communications / Electricity distribution Add access unit
Scope of adaptation: New batteries, PCS, direct flow, communication access and protection co-operation; Retain the former station-level EMS border with the grid to complete system-level enhancement under compatible conditions.

03 Interface Compatibility Matrix AS-IS vs TO-BE

Interface category Status (AS-IS) Target (TO-BE) Compatibility conclusion Key measures
Electrical interface DC 1000V / AC 690V
Networking 35kV 		DC 1000V / AC 690V
Networking 35kV 		Compatibility Unify busbar specifications; recheck connectors and combiner equipment
Communication Protocols Modbus TCP(PCS/BMS)
IEC 60870-5-104(EMS) 		Modbus TCP / IEC 104
Add IEC 61,850 (optional) 		Conditionality Protocol mapping and point-list upgrade; revalidate commands and return codes
Protection interface Protection.
Original whole value 		Protection retention
Add GOOSE / Chaining 		Conditionality Protection setting review; GOOSE table and trip-chain verification
Clock Sync SNTP
Internal clock 		PTP Main clock
SNTP Standby 		Upgrade Add PTP clock source;event timing
Mechanical structure Base / Cable Trench
Limited retention 		Add 10 Counter
Channel 1.2m 		Compatibility Basic review and earthquake proofing; fire spacing satisfied
Electrical interface: The main voltage level is consistent with the 35kV grid boundary, and the additional feeder is connected through the established transfer and switch, without changing the original grid boundary.

04 Boundary-risk-responsibility-closure map

Each AS-IS-TO-BE difference must have a construction decision, a person responsible, evidence and closure conclusion.
Serial number AS-IS and TO-BE differences Impact / Risk Engineering decisions Responsible persons Evidence/ Record Closed
01 Difference between EMS Communities Data point lost / mismaps Create protocol map and complete full-scale point return Master System Engineering Map v1.0/ Return Record Closed loop
02 BCU solid version inconsistent SOC calculation deviation Harmonize compatible versions and freeze algorithm parameters Battery Engineer / Validation record Closed loop
03 Protect the difference between fixed values and capacity Error / Refusal Recalculate and export controlled protected values Protection of engineers A value calculator / GOOSE test Closed loop
04 The clock system is not uniform Event time error Add PTP master clock and full-stop verification Communications Engineer PTP Report / Time Error Record Closed loop
05 There's no consistency in the old level of alarm. Warning Storm / Underreporting Unified alarm dictionary and event rules Transport Engineer V-Dictionary v1.2 / Return Record Closed loop
06 Fire chain and amplification equipment Connection failed. Add a fire link and complete full chain testing Fire Engineer Joint test report Closed loop
• EMS Community Productions does not match the dot version: The protocol map, dot-freezing and FAT/SAT regression test confirm compatibility, and interim changes to address or schematics are prohibited before switching.

05 Power outage windows and switching schemes

Power outage windows and temporary power supply

TIME
Power outage window 2025-05-14 00:00 – 04:30
4.5 hours
UPS
Temporary power supply Control, communications and critical controls maintained by UPS / temporary power supply
LOTO
Isolation and LOTO High pressure, straight current, auxiliary power stratification
BACK
Back path Restore original system configuration for any Gate failure

Toggle Decision Tree Simplified

Start Switch
Pass. Failed
New system ready?
Stop Switch
Restore original system
Pass. Failed
Networking
Observation Validation
Back to old configuration
Restore original system

protocol / version / protection / clock docking

COM
Protocol control Modbus / IEC 104 / IEC 61850
VER
Version Control Solid / Configuration Freezing with Git
PRO
Protection cooperation Protect fixed values, GOOSE and hard locks
CLK
Clock Sync PTP master clock + SNTP backup

06 Phased implementation and night break Line 2025-05-13 → 2025-05-14

Stage 0 Preparation and rehearsal 05-12 ~ 05-13 Day
  • Programme evaluation and reporting
  • Risk list confirmed
  • Switch script preview
  • Backup Program Exercise
G0 Pre-approved
Phase 1. Acceptance and inspection of equipment 05-13 15:00 – 18:00
  • New Device Installation Recognition
  • PCS / Battery live acceptance
  • Wire and ground check.
  • Configuration Version Freeze
G1 Equipment acceptance complete
Phase 2 Joint and simulation tests 05-13 18:00 – 22:00
  • Direct flow side insulation and breakout test
  • PCS single machine test
  • Communications and remote authentication
  • Protect and link check
G2 . . . .
Stage 3. Power outage switch 05-14 00:00 – 04:30
  • There is a system of isolation.
  • Full access to amplification equipment
  • Protection & Communications Switch
  • Gradual restoration of the grid
G3 · CUTOVER
Phase 4 Operation recovery 05-14 04:30 – 06:00
  • Ongoing status confirmed
  • Alerts and trend monitoring
  • 30min stability observation
  • Get back to normal.
G4. Restoration of passage
G0 Programme / Personnel / Return
G1 Equipment acceptance complete
G2 Electric / Commission Testing Pass
G3 Switch finished
Either Gate failed Back off immediately, not to the next stage.

• Proof of pre- and post-retrofit system comparison and operation

The effect of the amplification must be demonstrated by real operating data and not only by design capacity.
Key indicators Before remodeling AS-IS Modified TO-BE Change
Available capacity (MWH) 1.40 4.01 +186%
Available Power (MW) 1.00 2.10 +110%
Charge Efficiency RTE 89.3% 91.6% +2.3pp
Maximum temperature difference 8.7°C 4.3°C -4.4°C
Number of daily reports 36 7 -81%
Availability (30 days) 97.62% 99.31% +1.69pp

SOC and Capacity Validation

Maximum temperature difference

Power Response

Trends in alarms

08 Delivery and acceptance evidence

DWG

Red / Finish

Record repositioning, interface changes, cable and equipment set-up.

ICD

Interface and version baseline

Tables, protocols, solids, parameters, protection and clock versions.

SAT

SAT Receiving and Inspection Report

Evidence of functionality, protection, communication, locking and performance testing.

DATA

Run Package

Pre- and post-reform trends, SOE, alarm, power and temperature evidence.

TRAIN

Operation and Trading

Additional equipment operations, rollback process, emergency response and maintenance Training.

HAND

Transfer package

Documents, versions, spare parts, liability boundary and final closure records.

Definition of completion of rehabilitation projects: Not "New cabinet installed," but... AS-IS Verified → Compatibility Closed → Cutover Controlled → Operation Restored → Performance Proven → Evidence Archived I don't know. The project will only be truly completed if the existing systems are stable and resilient, with real data validation and complete evidence.