Lead Engineer - Battery Energy Storage System Testing and Validation

Lead - Product Testing and Validation

BESS Testing & Validation Lead

Role Summary

The BESS Testing & Validation Lead owns the end-to-end verification and validation (V&V) of utility-scale Battery Energy Storage Systems. This role covers test strategy, validation planning, lab setup, prototype testing, safety validation (UL 9540A, fire/thermal), system-level performance testing, and cross-functional coordination. The engineer ensures all BESS hardware, firmware, and integrated systems meet design, reliability, safety, and certification requirements before release.

Key Responsibilities

• Define the overall test & validation strategy of Battery modules, packs, racks, and containers
• PCS/Inverters, MS, EMS, and firmware, HVAC & thermal management systems
• Mechanical and safety systems (fire detection, suppression, ventilation)
• Develop Validation Master Plans (VMP), DVP&R, test cases, and test matrices.
• Lead testing of Electrical function (power performance, charge/discharge, SoC/SoH validation),BMS functional testing, Thermal system performance (HVAC, coolant loops, airflow, heat rejection),Communication & controls (Modbus, CAN, SCADA, EMS),Safety systems (shutdowns, interlocks, alarms)
• Validate system behaviour during Grid events (voltage/frequency excursions),Transients, ramp rates, and dynamic power commands, Fault injection tests (cell faults, temperature faults, communication failures)
• Lead internal and external testing for UL 9540 / UL 9540A thermal runaway validation,UL 1973 battery pack testing, IEC 62933 functional and safety testing, Fire, venting, suppression, and gas concentration tests
• Coordinate with 3rd-party certification agencies and accredited labs.
• Plan and execute Vibration, shock, drop, seismic tests, Thermal cycling, humidity, salt-mist, corrosion tests, Ingress protection tests (IP55/IP65),Long-duration cycle and aging tests, Evaluate system degradation, lifetime performance, and component reliability.
• Define test lab requirements (electrical, safety, HVAC, fire suppression).
• Procure, install, and maintain test infrastructure such as Cyclers, Environmental chambers, DAQs & logging systems, Load banks / Grid simulators,Fire/thermal measurement equipment
• Ensure safe test procedures and test lab SOPs.
• Analyze test data, system logs, and performance KPIs to identify design issues.
• Prepare detailed test reports, failure analysis documents, and corrective action recommendations.
• Lead root-cause analysis (RCA) with engineering teams.
• Cross functional collaboration with all relevant stake holders and provide feedback

Required Qualifications

• Bachelor’s or Master’s degree in Electrical, Mechanical, Mechatronics, Controls, or related engineering field.

Technical Skills

• Strong understanding of BESS architecture (cell → module → rack → container),Power electronics, PCS, and grid behaviour, MS & EMS functionality, Thermal management systems, Fire/thermal safety and UL 9540A principles, Skilled in using test equipment: power analysers, oscilloscopes, cyclers, load banks, CAN/Modbus tools.
• Knowledge of standards: UL 9540, 9540A, UL 1973, IEC 62109, IEC 62933, IEEE 1547.

Experience

• 6–12+ years in BESS testing/validation, Battery module/pack testing,Power electronics or inverter system testing
• Experience leading teams and managing cross-functional projects.
• Prior experience working with certification bodies highly preferred.