Senior Design Engineer – Thermal & Cooling Systems (BESS)
Location: Bengaluru, India
Experience: 8–12 Years
Function: BESS Product Engineering – Thermal Systems
About The Role
We are looking for a
Senior Design Engineer – Thermal & Cooling Systems to design, develop, and validate
thermal management solutions for utilityscale and commercial & industrial (C&I) Battery Energy Storage Systems (BESS). He will be Part of BESS system Engineer and responsible for designing and optimizing the thermal management systems.
This role focuses on
endtoend thermal system design, Heat Loss Calculation, ensuring safe operation, high reliability, optimal battery life, and compliance with stationary energy storage requirements. You will work closely with battery, enclosure, CFD, electrical, and system teams to deliver robust cooling architectures suitable for longduration, highpower stationary storage applications.
Key Responsibilities
Thermal Architecture & System Design
- Design and own thermal management architectures for battery racks, modules, and containers.
- Heat Loss Calculation
- Define cooling strategies for utilityscale and C&I BESS, considering:
- Environmental extremes
- Longduration operation
- Maintainability and serviceability
- System Design & Sizing: Design HVAC or liquid cooling systems tailored for BESS, including heat load calculations, system sizing, and equipment selection.
- Select and size thermal components including:
- Air and/or liquid cooling systems
- Heat exchangers, chillers, pumps, fans, ducting
- Develop thermal concepts aligned with system cost, reliability, and scalability goals.
- Hands on Experience with Simulations tools like ANSYS / SIMcenter etc..
Battery Thermal Management
- Ensure battery operation within defined thermal limits for:
- Safety
- Performance
- Cycle and calendar life
- Define thermal interfaces between:
- Battery cells/modules
- Cooling systems
- Mechanical enclosures
- Support thermal derating strategies in coordination with BMS and system controls teams.
- Cooling Loss Analysis: Calculate Auxiliary loads – Optimisation of Energy consumed by the cooling system - Improve overall round-trip efficiency of the BESS.
- Liquid Cool Plate / Heat sink design Knowledge is added Advantages .
Design Validation & Testing
- Plan and support thermal validation testing, including:
- Steadystate and transient thermal performance
- Environmental and stress testing
- Correlate analytical predictions and CFD results with test data.
- Familiarity with standards like NFPA 855, UL 9540, and IEC 62933.
- Participate in FAT, SAT, and site commissioning activities from a thermal perspective.
CrossFunctional Collaboration
- Work closely with:
- CFD simulation engineers
- Mechanical and enclosure designers
- BMS and system engineering teams
- Provide thermal inputs to systemlevel trade studies and design reviews.
- Support root cause analysis of thermalrelated field issues.
Required Skills & Experience
Core Technical Skills
- 8–12 years of experience in thermal system design for batteries, power electronics, EVs, or energy storage systems.
- Strong understanding of:
- Heat transfer (conduction, convection, radiation)
- Battery thermal behavior and safety limits
- Handson experience with:
- Air and liquid cooling system design
- Thermal component sizing and selection
- Familiarity with thermal testing methods and instrumentation.
System & Product Experience
- Experience working on utilityscale or C&I energy systems preferred.
- Understanding of thermal challenges in highvoltage, highenergy stationary systems.
- Exposure to relevant safety and reliability requirements for stationary storage.
Preferred Qualifications
- Bachelor's or Master's degree in Mechanical Engineering, Thermal Engineering, or related field.
- Experience with industry standards relevant to stationary BESS (IEC / UL preferred).
- Familiarity with CFD tools (working knowledge; detailed CFD ownership optional).
- Experience supporting field deployments and longterm product reliability.
Soft Skills
- Strong problemsolving and analytical skills.
- Ability to independently own complex thermal design problems.
- Effective communication in crossfunctional engineering teams.
- Detailoriented mindset with strong focus on safety and reliability.
