Production Growth without Immediate Grid Upgrade — in Spain
Project Overview
BESS for Transformer Capacity Expansion in Spain demonstrates how a 250kW/522kWh cabinet battery energy storage system can act as a virtual transformer upgrade for an industrial site. When new production lines raise peak demand beyond the available transformer and grid connection headroom, the BESS supplies short-duration boost power to cap site import within safe limits. The EMS coordinates import limiting, fast peak response, and controlled recharge to protect the transformer, maintain production continuity, and defer costly utility upgrades.
Project Background
Industrial expansion often collides with electrical infrastructure constraints. Upgrading a transformer or obtaining a higher contracted capacity can require long lead times, civil work, and utility approvals—especially for operating plants that cannot afford extended downtime. Meanwhile, process equipment such as motors, compressors, ovens, and material handling systems can create sharp peaks during start-up and batch transitions. A behind-the-meter BESS can supplement transformer capacity by shaving peaks and providing transient support, enabling the plant to scale production while keeping grid import within contracted limits.
Project Challenge
- Transformer and Contracted Capacity Constraint: Prevent overload and stay within the site import limit despite higher production-driven peaks.
- Fast Transient Demand: Track rapid load steps without instability, avoiding nuisance trips and voltage dips affecting sensitive equipment.
- Energy Readiness and Battery Protection: Maintain SOC headroom for peak events while respecting C-rate, temperature, and SOC boundaries.
FFD POWER Solution
FFD POWER deployed a 250kW/522kWh cabinet BESS integrated with an industrial EMS configured for transformer capacity supplementation. The EMS continuously measures grid import and enforces a configurable import cap aligned with transformer and contractual limits. When demand exceeds the cap, the PCS discharges to supply the difference, keeping the transformer within its safe operating region. During low-load periods, the system recharges under a power-limited profile to rebuild SOC headroom without creating new peaks.
System Specifications
- BESS POWER : 250 KW
- BESS capacity : 522 KWH
- Product used : Galaxy 261L Cabinet-type all-in-one BESS * 2
- Application : Transformer capacity expansion (peak shaving / boost)
- Architecture: EMS with grid import cap + fast peak response + controlled recharge & SOC readiness
Operational Logic: Grid Import Cap + Peak Boost + SOC Readiness
The EMS logic treats transformer loading as the primary constraint and dispatches the BESS as a buffering asset:
- Grid Import Limiting: enforces a site import cap; when load exceeds the cap, the BESS discharges to cover the difference and prevent transformer overload.
- Peak Response and Smoothing: responds quickly to load steps with ramp control to keep transitions stable and protect plant power quality
- SOC Readiness and Recharge Control: maintains a target SOC window for peak support; recharges in low-demand windows under a power limit to avoid new demand spikes.
