Lead Mechanical - BESS

Job description

Position Summary We are seeking a highly experienced Lead Mechanical Engineer specialising in Battery Energy Storage Systems (BESS) to join our growing Energy Storage Division. The successful candidate will own the end-to-end mechanical design, structural analysis, and certification of 20-foot ISO containerised battery enclosures and related infrastructure, from concept through commissioning. This is a senior individual-contributor and technical-leadership role that directly influences product architecture, manufacturing partners, and regulatory compliance strategy — including the full suite of relevant IEC and international standards. Key Responsibilities • Enclosure & Container Design • Lead the full mechanical design lifecycle of 20-foot battery container/enclosure systems, including structural frames, base skids, wall panels, roofing, doors, and lifting lugs. • Develop and own 3D CAD models and detailed engineering drawings (GD&T) for fabrication, using SolidWorks, CATIA, or equivalent parametric tools. • Define and manage BOM structures, part numbering, and revision control in PLM/PDM systems. • Specify and select enclosure materials (steel, stainless, aluminium, composites) based on corrosion class, fire rating, and thermal requirements. • Design internal layout for battery rack integration, cable management, thermal management, and auxiliary equipment (HVAC, fire suppression, electrical panels). • Drive Design-for-Manufacture (DFM) and Design-for-Assembly (DFA) reviews with contract manufacturers. • Ensure container dimensional and structural interface compliance with ISO 668 and ISO 1496-1 (series 1 freight container specifications). • Structural Analysis & FEA • Perform and lead structural analysis of enclosure assemblies under seismic, wind, snow, dead, and live load combinations per applicable codes (IBC, ASCE 7, Eurocode EN 1993 as needed). • Conduct or oversee Finite Element Analysis (FEA) using ANSYS, Abaqus, or SolidWorks Simulation for stress, fatigue, buckling, and modal analysis. • Specify and review welder qualifications, weld procedures (WPS/PQR), and non-destructive examination (NDE/NDT) requirements. • Produce and review structural calculation packages for permit submission and third-party PE-stamped peer review. • Regulatory Compliance & Certification • Ensure all designs meet FEMA requirements for Flood Insurance Rate Map (FIRM) zones, including flood-proofing, elevation certificates, and FEMA 348/FIA-TB-2 compliance. • Lead UL 9540 / UL 9540A, NFPA 855, IFC, and NEC 706 compliance reviews for containerised BESS installations. • Interface with Authorities Having Jurisdiction (AHJs), PE stamp requirements, and third-party certification bodies (UL, TÜV, Intertek, Bureau Veritas). • Manage seismic qualification per ICC-ES AC156, IBC Chapter 16, and ASCE 7-22 for site-specific risk categories. • Coordinate with EPC partners and site civil engineers on foundation loads, anchor bolt design, and geotechnical interface. • Apply and interpret the full IEC BESS standards suite across mechanical design, safety, environmental, and transport domains — see dedicated IEC Standards section below. • Thermal & Environmental Management • Define thermal management strategy (liquid cooling, HVAC, ventilation) to maintain cell and BMS temperatures within OEM-specified limits across ambient design range (typically −30°C to +50°C). • Conduct or review CFD analyses (Fluent, FloEFD, or similar) for internal airflow and hotspot mitigation. • Specify ingress protection (IP) ratings per IEC 60529 and NEMA enclosure classifications; design door seals, cable gland arrays, and ventilation baffles accordingly. • Ensure environmental endurance of enclosure per IEC 60068 test series (thermal cycling, damp heat, salt mist, vibration, shock). • Fire & Safety Systems Integration • Define mechanical interface requirements for aerosol, FM-200, CO?, or water-mist fire suppression systems per NFPA 855 and OEM requirements. • Specify deflagration venting panels, explosion-proof fittings, and duct penetration seals per IEC 60079-series (ATEX/IECEx) and NEC Class I Div 2 requirements. • Specify minimum ventilation rates for battery rooms/enclosures per IEC 62485-3 to prevent accumulation of flammable off-gases. • Collaborate with safety engineering to execute HAZOP, FMEA, and PHA for mechanical systems per IEC 62933-5-2 risk assessment methodology. • Battery Module & System Interface • Define mechanical mounting, vibration isolation, and thermal interface requirements for battery racks and modules, ensuring compliance with IEC 62619 and IEC 63056. • Verify UN 38.3 transport qualification evidence for all lithium cell and module assemblies; specify shock and vibration isolator requirements to maintain qualification compliance after installation. • Specify module-level mechanical boundary conditions (load paths, clearances, cable routing) in coordination with battery OEM and electrical teams. • Technical Leadership & Project Management • Act as technical lead and mentor for junior/mid mechanical engineers on the BESS product team. • Drive design reviews (PDR, CDR, FDR) and manage action items to closure. • Coordinate across electrical, controls, civil, and procurement disciplines to maintain interface control documents (ICDs). • Develop and execute mechanical qualification test plans (vibration, drop, IP, thermal cycling) with internal and external test labs. • Support project management on schedule, scope, and risk for mechanical deliverables. IEC & INTERNATIONAL STANDARDS REFERENCE The table below lists the primary IEC and related international standards the candidate must be able to apply, interpret, and cite in design documentation, test plans, and certification submissions. This list reflects the current BESS regulatory landscape; the candidate is expected to monitor IEC TC 120, TC 21, and TC 21A work programmes for emerging revisions. Standard Scope & Subject **BESS Mech