Lead Mechanical - BESS

Larsen & Toubro; Bengaluru; On-site; INR 4,000,000 - 7,000,000; Full time

Job summary

Larsen & Toubro in Bengaluru seeks a Lead Mechanical Engineer to own the end-to-end mechanical design and certification of 20‑foot battery container enclosures for the Energy Storage Division. You will drive structural analysis, material selection, and DFx, coordinating with manufacturing partners and regulatory bodies.

The role requires senior technical leadership, collaboration across electrical, controls, and civil teams, and extensive experience with IEC/NFPA/UL standards relevant to

Qualifications

• Must own end-to-end mechanical design for battery enclosures and related infrastructure.
• Must perform structural analysis per relevant codes and standards.
• Experience with regulatory compliance and certification for BESS installations.

Responsibilities

• Lead full mechanical design lifecycle for 20‑ft battery container/enclosure systems (frames, panels, doors, lugs).
• Develop 3D CAD models and drawings (GD&T) for fabrication; manage BOMs and revisions in PLM/PDM.
• Define enclosure materials selection based on corrosion, fire rating and thermal needs; layout integration for racks, cables, HVAC.
• Drive DFM/ DFA reviews with contract manufacturers and ensure ISO container interface compliance.
• Perform/oversee FE analyses (seismic, wind, snow, dead, live loads) using ANSYS/Abaqus/SWSimulation.
• Coordinate regulatory review activities with AHJs and third-party cert bodies; support PE stamped submissions.

Skills

End-to-end mechanical design

Structural analysis

Regulatory compliance

Project leadership

Tools

SolidWorks

CATIA

ANSYS

Abaqus

SolidWorks Simulation

PLM/PDM

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 DesignLead 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 & FEAPerform 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 & CertificationEnsure 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 ManagementDefine 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 IntegrationDefine 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 InterfaceDefine mechanical mounting, vibration isolation, and thermal interface requirements for battery racks and modules, ensuring compliance with IEC 62619 and IEC 630
• 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 ManagementAct 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.
StandardScope & SubjectBESS Mechanical ApplicabilityA | BESS System‑Level — IEC TC 120 (IEC 62933 Family)IEC 62933‑1EES systems — Terminology and definitionsBaseline vocabulary for all BESS documentationIEC 62933‑2‑1Unit parameters and testing methods — Basic requirementsContainer‑level acceptance test procedures & KPIsIEC 62933‑2‑2Performance and capacity testing — Cycle‑life & calendar‑lifeStructural and thermal design life verificationIEC 62933‑3‑1Planning and performance assessment of EES systemsContainer sizing, layout, and system modellingIEC 62933‑4‑1Guidance on environmental issuesLCA, material restrictions, end‑of‑life designIEC 62933‑4‑2Requirements for environmental assessmentDisposal, recycling, RoHS/REACH interfaceIEC 62933‑5‑1Safety requirements for grid‑integrated EES systemsOverarching safety framework, grid‑connected containersIEC 62933‑5‑2Safety requirements — electrochemical‑based EES systemsHazard ID, risk assessment, protective measuresB | Cell & Battery Safety — IEC TC 21 / TC 21AIEC 62619Safety requirements for secondary Li cells — industrial applicationsThermal runaway prevention, BMS req., abuse toleranceIEC 63056Safety requirements for secondary Li cells for EES systemsSystem‑level integration safety; complements IEC 62619IEC 62485‑3Safety requirements — stationary batteries (ventilation)