Revision D R2.0 — Common DC Link • DC/DC Conversion • Supercapacitor • BESS • Switching & Protection
Hybrid Energy Recovery Pump System (H.E.R.P.S)
The H.E.R.P.S Revision D R2.0 energy-storage architecture combines the common DC-link system, bidirectional DC/DC conversion, supercapacitor transient-energy subsystem, LiFePO₄ battery energy-storage system, high-voltage switching, isolation, protection and supervisory control into one coordinated electrical-energy platform.
The architecture manages recovered electrical energy and transient power exchange without representing the machine as self-powering. The main pump remains capable of normal grid-supplied operation while the energy-storage systems provide controlled buffering, transient support and energy-management functions.
The Revision D common DC link forms the central DC-energy interface between compatible regenerative conversion equipment, energy-storage converters and transient-energy devices.
| Parameter | Revision D R2.0 Baseline |
|---|---|
| Nominal DC-Link Voltage | 750 VDC |
| Controlled Operating Range | 650–800 VDC |
| Hardware Overvoltage Protection Baseline | ≥820 VDC |
| Primary Function | Central controlled DC-energy transfer interface |
| Connected Functions | DC/DC conversion, supercapacitor system, BESS interface and regenerative power architecture |
The battery-energy-storage interface uses controlled bidirectional DC/DC conversion between the BESS voltage domain and the common DC link.
| Parameter | Revision D R2.0 Baseline |
|---|---|
| Converter Function | Bidirectional BESS DC/DC conversion |
| Continuous Power | 160 kW |
| Short-Duration Peak Baseline | 200 kW for ≤30 seconds |
| Energy Direction | Charge and discharge |
| Primary Interface | BESS ↔ Common DC Link |
Converter operation remains subject to DC-link voltage, BESS limits, battery-management permissions, electrical protection and the applicable machine operating mode.
The supercapacitor subsystem is the rapid-response energy buffer within the H.E.R.P.S Revision D DC architecture. It is intended for short-duration, high-power charge and discharge events rather than long-duration stored-energy duty.
| Parameter | Revision D R2.0 Baseline |
|---|---|
| Voltage Class | 750 VDC |
| Capacitance | 16 F |
| Converter Function | Bidirectional |
| Short-Duration Power Class | ≥250 kW |
| Primary Duty | Transient-energy buffering and rapid DC-system support |
H.E.R.P.S Revision D uses a dedicated LiFePO₄ battery energy-storage system divided across two cabinet zones and supervised by the Battery Management System.
| BESS Parameter | Revision D R2.0 Baseline |
|---|---|
| Battery Chemistry | LiFePO₄ |
| Series Configuration | 192S |
| Capacity | 160 Ah |
| Nominal Pack Voltage | 614.4 VDC |
| Nominal Stored Energy | 98.304 kWh |
| Module Architecture | 12 × 16S / 160 Ah modules |
| Cabinet Architecture | Two cabinet zones |
The BMS supervises battery operating condition and provides the battery-specific protective layer required for controlled operation of the energy-storage system.
The Revision D energy architecture includes controlled high-voltage switching and isolation so the DC link, BESS and related energy-storage equipment can be safely connected, disconnected and placed into defined service states.
High-capacitance DC systems cannot be connected as an uncontrolled step load. Revision D therefore incorporates controlled precharge and discharge functions as part of the switching architecture.
The energy-storage architecture interfaces with the wider H.E.R.P.S electrical system through the Revision D AC switchgear and regenerative AFE/VFD architecture.
The H.E.R.P.S Revision D battery and supercapacitor systems support the machine's managed energy architecture. They do not create additional energy and do not replace the external source required to operate the main pump.
The pump remains capable of grid-powered operation with the BESS isolated. Recovered electrical energy may be managed through the common DC architecture only where the corresponding hydraulic recovery energy is genuinely available.
Grid export is not enabled by default within the Revision D baseline. Export capability requires separate engineering, protection studies, utility coordination and formal approval before implementation.
Revision D combines hardware protection, power-electronic protection, BMS protection and supervisory control rather than relying upon one software layer for electrical safety.
Revision D integrates electrical-energy data into the wider H.E.R.P.S PLC/HMI/SCADA architecture so the storage and switching systems can be monitored alongside the hydraulic and mechanical systems.
| State | Purpose |
|---|---|
| Isolated | Energy-storage subsystem disconnected from the common DC architecture |
| Precharge | Controlled charging of the DC-link capacitance prior to main connection |
| Standby | System energized and available without commanded energy transfer |
| BESS Charge | Controlled transfer of permitted energy into battery storage |
| BESS Discharge | Controlled transfer of battery energy to the DC architecture |
| Supercapacitor Charge | Rapid transient-energy absorption |
| Supercapacitor Discharge | Rapid short-duration power support |
| Fault Isolation | Automatic or commanded isolation following a detected abnormal condition |
This page presents the public Revision D R2.0 energy-storage and switching architecture. It does not replace supplier-certified battery data, converter certification, final protection studies, final cable schedules, final settings or the signed as-built configuration record.
Final vendor models, final converter parameters, final BMS settings, final protection settings, detailed cable sizing and other controlled implementation information remain subject to the applicable engineering, procurement, validation, FAT/SAT and as-built processes.
The common DC link, DC/DC conversion, supercapacitor and BESS architecture forms part of the complete H.E.R.P.S Revision D multi-volume conceptual engineering system.
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HERPS-VOL-13-COMMON-DC-LINK-DC-DC-CONVERSION-AND-SUPERCAPACITOR-SYSTEM-REV-D-R2.0.webp
HERPS-VOL-14-BESS-CABINETS-MODULE-ARCHITECTURE-AND-BATTERY-SAFETY-REV-D-R2.0.webp
HERPS-VOL-12-VFD-AFE-SWITCHGEAR-AND-AC-POWER-DISTRIBUTION-REV-D-R2.0.webp
HERPS-VOL-15-PLC-HMI-SCADA-INSTRUMENTATION-AND-FIELD-IO-REV-D-R2.0.webp