Component Component
Cell
CELL
Line
Busbar
Melt
Fuse
Pass
Sensor
Wind
Fan / Pump
Valve
Valve
SYSTEM INTEGRATION ENGINEERING
Integrate multiple subsystems into one system
Energy Storage Systems
From demand definition, system architecture, space set-up, interface boundary, control locks, heat management, fire safety to test delivery, the real integration of batteries, PCS, power distribution, EMS, liquid cooling and fire protection into a set of operated, verifiable and maintenanceable Energy Storage Systems.
Safe
Security priority Clear boundaries
Coordination
Efficient coordination System Connection
Check
Could not close temporary folder: %s The evidence is closed.
Hand it over.
Deliverable Project controlled
Five-layer integration view: one system, different dimensions
Mechanical space layer
Structure, overhaul, access, maintenance
Electrical power layer
Direct flow, communication, protection and location
Control chain layer
Control, communication, locking
Heat management and fire level
Liquid cooling, exhaust, fire protection, pressure relief
Project Engineering Layer
Interface, delivery, version, evidence
Level structure: from component to site
Subsystem
B
BMS
D
DC System
P
PCS
A
AC System
Cold
HVAC
Fire
Fire System
E
EMS
Cabinet
System System
Energy Management EMS
Power Change PCS
Battery management BMS
Safety interlock Interlock
communications systems. Network
Station
Superior grid. Grid
Pressure-up system Transformer
Connect Point PCC
Communications Comm.
Spatial zoning and maintenance corridors
Battery chamber
Checking the tunnel.
PCS module
Checking the tunnel.
Electrical distribution module
Checking the tunnel.
Control.
Check the tunnel.
Heat management module
Check the tunnel.
Fire cabin.
Check the tunnel.
Personnel access
Wireways
Power Channel
The cooling tunnel.
Safe distance
Direct to grid: one-time single-line system Figure Alignment with Physical Space
Rack Batteries Battery Racks
DC Direct flow. DC Combiner
SW DC switch DC Switch
Cont DC contactor DC Contactor
PCS PCS Transform PCS
AC Communication Switches AC Switch
TR step-up transformer Transformer
PCC Grid Connection Status PCC / Grid
Control, state and chain.
EMS Main Station
On-site controller A
Field controller B
Field controller C
BMS
PCS
PCS control cabinet
Environment / Fire
Critical state and chain Example:
| Chain number | Trigger condition | Action Objects | Action Results | Priority | Status |
|---|---|---|---|---|---|
| ILK-101 | Cluster overpressure | PCS / Contact | Stop Charging | P0 | :: Normal |
| ILK-102 | The flow is abnormal. | Wind/ Pump | Run down | P1 | :: Normal |
| ILK-103 | Fire alarm. | High pressure / PCS | Isolate the broken cabinet. | P0 | :: Normal |
| ILK-104 | It's off limits. | Control Systems | Enter maintenance mode | P1 | :: Normal |
| ILK-105 | Interrupted communications | EMS / PCS | Execute Local Policy | P2 | :: Normal |
Thermal management and fire co-design
Cold
It's the main route.
Liquid cooling + air-cooling backup
Temp
Temperature control
Target temperature difference 5°C
Smoke
Smoke/gas detection
Multi-parameter early warning
Extermination
A cabinet fire.
Connect BMS / PCS
Line
Flow and excretion
Wind / Depressure Channel
Interface Liability Matrix and ICD List Selected
| Interface Fields | Interface | Responsible party A | Responsible party B | ICD Number | Status |
|---|---|---|---|---|---|
| Mechanical | Courtroom connection | Reserve | Construction | ICD-M-001 | Closed |
| Mechanical | Liquid-cooling interface | Reserve | Liquid cooling supplier | ICD-M-002 | Closed |
| Electrical | Communication connection | Reserve | Total | ICD-E-002 | Closed |
| Control | Communications interface | Reserve | EMS | ICD-C-001 | Closed |
| Communications | Platform access | Reserve | Owner | ICD-C-002 | Closed |
Conflict identification and concerted resolution
Mechanical conflicts Box, liner and structure interference
Electrical conflict Cable paths and space maintenance conflicts
Hot conflicts Air currents clash with heat vents
Adjust Device Configuration
Optimizing cable course
Adjust interface position
Run mode status recurrence
Wait. Standby Standby
Fill Charge Charging
Fire! Power discharge. Discharging
Down Reduction Derating
And so... Fault Fault
Kai! Black Start Black Start
Standby:
PCS stand-by, systems complete self-checking, support systems maintained.
Fault response order Priority from high to low
1 Identification
BMS / EMS / SCADA
2 Alarm
Sound/ Platform
3 segregated
High pressure / cabinet level
4 Disposal
Reduction / Fire
5 Restore
Check / Reset
Design evaluation and issue closed loop
| Question number | Problem description | Risk | Responsible party | Status | Date of submission | Close Time |
|---|---|---|---|---|---|---|
| ISS-2024-017 | Inadequate cable maintenance space | Medium | Reserve | Closed | 2024-05-08 | 2024-05-07 |
| ISS-2024-021 | Fire interface position optimization | High | Fire | Closed | 2024-05-12 | 2024-05-11 |
| ISS-2024-025 | There's a large temperature difference between currents. | Medium | Thermal management | Closed | 2024-05-18 | — |
| ISS-2024-031 | Communications equipment redundancy confirmed | Low | Control | Closed | 2024-05-20 | — |
Certification and delivery chain of evidence
Simulate
Simulation verification
Simulation
CFC/ Electrical/ System Completed
CFC/ Electrical/ System Completed
HIL
Control and algorithm authentication
HIL
Control / trouble injection Completed
Control / trouble injection Completed
FAT
Inspection and inspection at the plant
FAT
Full Validation Pass.
Full Validation Pass.
SAT
On-site inspection and acceptance
SAT
On-site system coordination Pass.
On-site system coordination Pass.
Transport
Run Authentication
O&M
Run a continuous validation Ongoing
Run a continuous validation Ongoing
Key validation records Example:
| Authentication Type | Report number | Version | Date | Conclusions |
|---|---|---|---|---|
| Simulation Report | SIM-2024-042 | V1.0 | 2024-04-10 | Pass. |
| HIL Test | HIL-2024-055 | V1.0 | 2024-04-20 | Pass. |
| FAT Report | FAT-2024-066 | V1.0 | 2024-05-05 | Pass. |
| SAT report | SAT-2024-072 | V1.0 | 2024-05-18 | Pass. |
Engineering baseline
Name of project 5 MW / 10 MWh Project Energy Storage Systems
System Version V2.0
Communication voltage 0.4 kV
Direct current voltage 1200 Vdc
Ambient temperature -20 ~ 50°C
Standard system IEC 62933 / GB/T 34120
List of deliverables Core
Figure Systems Integration
Single One system chart
Rectangular Interface Matrix
BOM BOM List
ICD ICD List
Measure Test report
Version and change records
| Version | Date | Change explanation | Status |
|---|---|---|---|
| V0.1 | 2024-03-12 | First edition programme | Archived |
| V1.0 | 2024-06-22 | Complete review and update | Archived |
| V2.0 | 2024-05-20 | Complete optimization and validation | Current |