System integration

Storage, solar, DG and chargers, working as one

Most projects combine equipment from several makers: batteries, inverters, solar, diesel generator (DG) set controllers, switchgear, chargers, meters and software. Each works on its own. As system integrators, we make them work together, and we take responsibility for the interfaces between them.

Fig.: Many makers, one system. Schematic, not to scale.

The interfaces

Problems live at the joins

In EPRI's analysis of battery failures, most of the failed elements were in the balance of system and the controls, not in the cells. So we engineer the joins.

Fig.: Seven interfaces meet at one owner. Schematic, not to scale.
  1. DC side

    String design, fusing and protection coordinated so one rack can't feed a fault in another; insulation monitoring; cables sized with margin.

  2. AC side, switchgear & protection

    Power conversion system (PCS) settings, transformer and LT/HT panels, relay coordination, anti-islanding, earthing and surge protection, with grid settings agreed with the distribution company (DISCOM).

  3. Generator interface

    Changeover, ATS and synchronising panels reworked so the battery and the diesel or gas genset hand over cleanly, in both directions.

  4. Controls & EMS

    One control philosophy, run by the energy management system (EMS), across battery, solar inverters, genset controllers and chargers: who leads, who follows, and what happens when the grid goes.

  5. Communications & cybersecurity

    Meters, the battery management system (BMS), PCS and chargers talking over Modbus, IEC 61850, IEC 60870-5-104 or the Open Charge Point Protocol (OCPP). Protection signals are kept separate from monitoring networks, and remote access is controlled, with no default passwords.

  6. Thermal & fire systems

    Cooling, gas and smoke detection, suppression and ventilation interlocked with the BMS and PCS, so an alarm leads to a safe shutdown, not a surprise.

  7. Civil & site

    Plinths, drainage, cable trenches, fencing, access for maintenance and fire services, and corrosion protection near the coast.

The CEA's 2026 construction standards keep protection, interlocking and tripping channels physically and logically separate from SCADA and monitoring channels, and have the EMS take set-points over IEC 60870-5-104, Modbus TCP or IEC 61850.

Source: EPRI, Insights from EPRI's BESS Failure Incident Database: Analysis of Failure Root Cause (opens in a new tab) (May 2024).

Source: CEA, Technical Standards for Construction of Electrical Plants and Electric Lines (Amendment) Regulations, 2026 (opens in a new tab) (Gazette, 23 June 2026).

Architectures

Seven ways storage joins a site

Seven common ways a battery energy storage system (BESS) connects to the equipment already on a site, what each one involves, and the decisions to settle before design.

Schematic, not to scale.

Solar + storage retrofit (AC-coupled)

Add a battery with its own PCS to an existing solar plant, with minimal change on the solar side.

What's involved

  • Existing PV inverters
  • Battery + PCS
  • EMS
  • Export/zero-export control

Decisions to make

  • Metering arrangement and export limits
  • Where to connect (LT panel or HT)
  • Solar-shift vs peak-shave priority
Schematic, not to scale.

New hybrid plant (DC-coupled)

Solar and battery share an inverter; the battery can capture energy that would otherwise be clipped.

What's involved

  • PV array
  • Battery
  • Hybrid inverter / shared PCS
  • EMS

Decisions to make

  • DC/AC ratio
  • Inverter headroom at high solar
  • Battery charge from grid or solar only
Schematic, not to scale.

Genset + BESS hybrid

A hybrid controller decides when the diesel or gas genset starts; the battery handles transients and light loads; changeover is reworked.

What's involved

  • Genset and controller
  • Battery + PCS
  • Hybrid controller
  • ATS / synchronising panel

Decisions to make

  • Start/stop thresholds
  • Minimum genset loading
  • Transfer sequence and site restart after a blackout
Schematic, not to scale.

UPS + BESS for critical loads

The UPS keeps its short, instant job on the most sensitive loads; the battery system carries the wider site for longer and does daily work the rest of the time.

What's involved

  • Existing UPS
  • Battery + PCS
  • Transfer switching
  • Load-shedding controller

Decisions to make

  • Which loads sit on the UPS and which on the BESS
  • Autonomy needed
  • Islanding design and approval
Schematic, not to scale.

BESS + EV charging

The battery buffers fast chargers, and charger power is managed dynamically against the site limit.

What's involved

  • DC and AC chargers
  • Battery + PCS
  • EMS with charger load management
  • OCPP to charging software

Decisions to make

  • Site import limit
  • Buffer energy vs expected sessions
  • Tariff category and metering
Schematic, not to scale.

Islandable microgrid

Grid-forming PCS, transfer switching and load shedding keep critical loads running when the grid is down.

What's involved

  • Grid-forming PCS
  • Transfer switch
  • Solar and genset
  • Load-shedding controller

Decisions to make

  • Which loads stay on
  • Anti-islanding and reconnection
  • Protection in island mode

Grid-forming PCS is an equipment feature we specify where a design needs it.

Schematic, not to scale.

Multi-site monitoring

Several sites report to one monitoring layer (Energy 107), with common alarms and reports.

What's involved

  • Site gateways
  • Energy 107
  • Alarm routing to O&M

Decisions to make

  • Data points and sampling
  • Cyber and access model
  • Report formats
About Energy 107

Source: NREL (now NLR), Evaluating the Technical and Economic Performance of PV Plus Storage Power Plants (opens in a new tab) (August 2017).

Vendor-neutral

We choose equipment on evidence

We don't represent a single battery, inverter or charger maker, and we don't sell from a catalogue. When a project includes supply, we procure batteries, PCS, chargers, switchgear, meters and monitoring hardware for that project, scored against published criteria, and we show you the scores.

Safety evidence
Cell, pack and system certificates; UL 9540A test data; the maker’s incident history.
Performance terms
AC-to-AC efficiency definition, degradation curve, depth of discharge, augmentation terms.
Warranty & exclusions
What is covered, for how long, and what voids it.
Service in India
Engineers, spares and response time within reach of your site.
Data access
Raw BMS data, open protocols, no lock-in to one monitoring platform.
Compliance
Fit with the CEA 2026 BESS regulations, BIS/NABL requirements for chargers, and your DISCOM’s requirements.
Scheme conditions
Local-content or other conditions where a funding scheme applies.
End-of-life terms
Take-back, EPR registration and who recycles the batteries.
Total cost over life
Purchase, installation, auxiliaries, maintenance, augmentation and end of life.
Fig.: Every option scored against the same criteria. Schematic, not to scale.

Commissioning

Commissioning is where problems get caught

Fig.: Thermal checks on every termination before energisation. Schematic, not to scale.

72% of failures with a known system age happened during construction, commissioning or the first two years of operation.

Source: EPRI, Insights from EPRI's BESS Failure Incident Database: Analysis of Failure Root Cause (opens in a new tab) (May 2024).Based on incidents with enough public root-cause information: a trend, not a forecast.

Tests before handover

  1. Factory acceptance testWitnessed at the factory where the project warrants it: test reports, BMS behaviour, interlocks.
  2. Pre-commissioningInsulation resistance, polarity, torque and thermal checks on every DC and AC connection; coolant fill and leak test.
  3. Functional & safety testsBMS alarms and trips, fire-system interlocks, emergency stops, door and ventilation alarms, PCS protection.
  4. EMS mode testsPeak shaving, time-of-day (ToD) schedule, backup transfer, genset and charger interaction, run as they will run in service.
  5. Performance testsAvailable energy and round-trip efficiency to IEC 62933-2-1.
  6. Power-quality checkHarmonics and power factor at the point of connection with the PCS and chargers running.
  7. Inspection & handoverElectrical Inspectorate inspection, commissioning report, training and handover dossier.

Accountability

One owner for every interface

When several makers each own a box, the gaps between the boxes can end up belonging to nobody. As integrator, we sign up for those gaps in the interface responsibility matrix.

Who owns each interface, with and without a named integrator
InterfaceTypical position without a named integratorWith CHE Energy as integrator
Battery ↔ PCSBattery maker and PCS maker each point to the otherCHE Energy
PCS ↔ site protection and gridElectrical contractor, by defaultCHE Energy
EMS ↔ genset controllerOften unassignedCHE Energy
EMS ↔ chargers (OCPP)The charger vendor, for its own units onlyCHE Energy
Fire system ↔ BMS shutdownFire contractor and battery maker separatelyCHE Energy
Meters ↔ reportingThe site teamCHE Energy

“Typical position” describes a common pattern, not any named project.

Fig.: Who owns the joins. Schematic, not to scale.

Questions about integration

Usually. We review datasheets, protocols and warranty terms first. If a combination isn't supported by the maker, we'll tell you before any work starts.

It can, depending on how it connects. We check the solar inverter terms and your net, gross or open-access arrangement, and involve the DISCOM where needed.

Often, with changes to the changeover or synchronising logic. We survey the panel and the genset controller first, and design the hand-over sequence in both directions.

Modbus TCP and RTU, IEC 61850 and IEC 60870-5-104 for storage and grid equipment (the CEA's 2026 standards name Modbus TCP, IEC 61850 and IEC 60870-5-104 for BESS set-points), and OCPP 1.6J and 2.0.1 for chargers.

On every site: separate protection from monitoring networks, remove default passwords, use named accounts and controlled remote access, and manage firmware under change control. For generation and storage of 50 MW and above, the CEA Cyber Security in Power Sector Regulations 2026 apply from 1 April 2027.

Us, if we're your integrator or operations and maintenance (O&M) partner. We diagnose at system level and handle warranty claims with the makers.

Start with a conversation

Send us your single-line diagram. We'll check the joins.

A phone call is enough to start. If you have them, 12 months of electricity bills, 15-minute meter data, DG running hours and any EV plans let us come back with a first view of what fits.