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Basic & Detailed Engineering for a 500 MW/1000 MWh BESS

Tata Consulting Engineers Limited (TCE), established in 1962, is a premier global integrated engineering consultant, delivering end-to-end services from concept to commissioning. With a robust track record of successful projects in over 65 countries and a sustained double-digit five-year CAGR, TCE brings extensive expertise in energy infrastructure. This experience includes a strong focus on Transmission and Distribution (T&D) projects, covering voltage levels from 11kV to 765kV globally. TCE’s T&D team has delivered extensive solutions in engineering and design for grid substations, transmission lines, power system studies, and Battery Energy Storage Systems (BESS).

This case study demonstrates TCE’s capabilities in developing a grid-connected BESS with a capacity of 500 MW/1000 MWh, addressing energy stability, demand response, and grid resilience through optimised storage solutions.

Scope of Work

Engineering and Design

Battery Sizing and Component Optimisation: TCE carried out comprehensive analyses to meet specific RFs requirements, ensuring optimal battery sizing. This included assessing Depth of Discharge (DoD), State of Charge (SoC), ambient conditions, and Round-Trip Efficiency (RTE) to determine the best configuration.
Layout and Configuration Design: Multiple layout options were developed for the 13-acre site, evaluating building and container configurations for efficient space utilisation. The final selection was an RCC structure with compartmentalised rooms, chosen for its economic benefits, safety considerations, and reduced construction time.
Single-Line Diagrams (SLDs): TCE prepared detailed SLDs for various configurations, ensuring seamless integration of the BESS with grid infrastructure.
Tender Support and Bill of Quantities (BoQ): TCE contributed to the development of tender specifications for electrical and civil aspects, providing a comprehensive BoQ for streamlined procurement.
System Calculations: o RTE and Power Loss Assessment: Evaluated power loss and RTE to align with system efficiency targets. o Auxiliary Load Calculations: Designed an auxiliary load system to support essential operations while optimising power consumption.
Control System Architecture: TCE designed a robust control system architecture to ensure reliable, responsive battery management aligned with grid requirements.
Balance of Plant Engineering: Engineering support was provided for essential plant systems, including HVAC and fire protection within the selected building structure.
Electrical Load Flow and Short Circuit Studies: TCE conducted load flow and short-circuit studies, ensuring system resilience and stability under various operational scenarios.
Interface and Equipment Drawings Review: Comprehensive review of equipment drawings ensured integration with BESS design requirements and seamless interface with the grid.

Value Engineering

TCE’s value engineering approach focused on creating a cost-effective, high-performing, and compact BESS solution:

Capacity Optimisation and Configuration Selection: The team evaluated different battery types and configurations, leading to the selection of five-winding transformers to minimise space and reduce the number of 33kV medium-voltage panels, resulting in cost savings.
Optimised Building Layout: Positioning a high-capacity BESS within the limited 13-acre site posed significant design challenges. After evaluating ground-floor and multi-storey structures, TCE selected an RCC building for its cost-effectiveness and safety features.

TCE's Transmission & Distribution (T&D) Expertise

TCE has decades of experience in the T&D sector, having executed projects with voltage levels ranging from 11kV to 765kV across the globe. The T&D team has a proven track record in engineering and design for grid substations, transmission lines, and power system studies. In particular, the team’s experience in BESS projects has enabled TCE to provide optimised solutions in energy storage, leveraging in-depth knowledge of the complex interactions within T&D systems.

Results and Key Takeaways

This project showcased TCE’s expertise in large-scale BESS solutions, which enhance energy resilience and stability. The RCC structure optimised construction costs, while the strategic selection of equipment reduced both power loss and auxiliary load requirements. By integrating advanced T&D experience with energy storage solutions, TCE successfully delivered a reliable, scalable BESS designed to meet both current and future grid demands, underscoring TCE’s role as a leader in global energy consulting.

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Basic & Detailed Engineering for a 500 MW/1000 MWh BESS