One-stop integrated solution for the design of energy storage pipeline systems, covering both transmission and distribution pipelines for energy storage power stations.

　　For 600‑meter‑class energy storage power stations, a full‑life‑cycle solution encompassing design, material selection, installation, and operation & maintenance must be developed to ensure safe, efficient, and cost‑effective system performance. The design is elaborated across four dimensions: technical architecture, material selection, flow distribution, and safety protection.

　　I. Hierarchical Pipeline Architecture Design

　　Adopts a three-level pipeline layout:

　　- Primary main pipeline: A 316L stainless steel pipe (DN50) is selected, with a total length of approximately 150 meters, and is installed in the core area of the energy storage power station to handle high-pressure coolant delivery. The pipeline is equipped with a double-flange connection design and incorporates a 5% safety margin to accommodate pressure fluctuations under extreme operating conditions.

　　- Secondary liquid–gas separation pipeline: Made of PA12 nylon tubing (DN25), with a total length of approximately 250 meters, it connects the primary main line to the battery cluster. The pipeline is equipped with an automatic air‑vent valve and a three‑piece stainless steel ball valve, enabling gas–liquid separation and dynamic flow regulation.

　　- Tertiary branch lines: PE flexible hoses (DN14), with a total length of approximately 200 meters, are directly connected to the battery pack’s liquid‑cooling plate. Quick‑connect fittings are installed at the ends of the lines, enabling rapid maintenance and replacement of individual battery packs.

　　II. Traffic Load Balancing Technology

　　Based on fluid dynamics simulations, a variable-diameter tee is employed to achieve precise flow distribution:

　　- Calculate the flow rate requirements for each battery‑pack branch line (e.g., 3.4 L/min), and balance pressure losses by adjusting the inner diameter of the horizontal outlet of the tee fitting in increments of 5.6 mm to 10 mm.

　　- The main pipeline flow rate shall be designed to be no less than 120 L/min, ensuring that the system’s total pressure drop is kept within 0.2 MPa to prevent a decline in cooling efficiency due to excessive pressure loss.

　　III. Enhanced Weather Resistance of Materials

　　In response to outdoor environmental challenges, a materials upgrade program has been implemented:

　　- The metal piping is made of 316L stainless steel, with a salt-spray corrosion resistance rating of C5, making it suitable for high-humidity coastal environments.

　　- The plastic piping incorporates a TIE+PP three-layer composite structure, enhancing hydrolysis resistance and extending its service life to over 15 years.

　　- Key connecting components are equipped with VOSS quick‑connect fittings, enabling operation across a wide temperature range of –40°C to +120°C and preventing low‑temperature embrittlement and high‑temperature deformation.

　　IV. Multi-Layered Security Protection System

　　Building a four-tiered security barrier:

　　1. Pressure Protection: A pressure safety valve (PSV) is installed on the high-pressure pipeline section, with its set opening pressure equal to 1.25 times the system’s maximum operating pressure.

　　2. Leak Monitoring: Ultrasonic sensors are deployed at critical pipeline nodes to detect micro-leaks in real time (≥0.1 L/min), triggering audible and visual alarms and automatically shutting off the fluid supply.

　　3. Thermal Stress Compensation: Install bellows expansion joints at pipe supports to absorb axial displacements caused by temperature changes (ΔT ≥ 50°C), thereby preventing joint loosening.

　　4. Emergency Drainage: Install emergency drainage valves in the low-lying areas of the energy storage station and connect them to the fire‑fighting drainage system to ensure rapid diversion of leaked fluids, thereby preventing secondary contamination.

　　V. Full Lifecycle Management

　　Achieving intelligent operation and maintenance of piping systems through a digital platform:

　　- Deploy IoT sensors to collect real-time data on pipeline pressure, flow rate, and temperature, and generate health assessment reports.

　　- Develop a preventive maintenance model that, based on parameters such as pipeline corrosion rates and vibration frequencies, issues early warnings six months in advance of replacement needs.

　　- Offers a modular upgrade solution that enables seamless integration of additional battery clusters into the piping system as storage capacity is expanded in the future.

　　This solution, leveraging five key technical modules—hierarchical architecture, traffic optimization, material reinforcement, security protection, and intelligent operations and maintenance—meets the stringent requirements of 600-meter‑class energy storage power stations for high reliability, long service life, and low maintenance in their transmission and distribution pipeline systems, thereby providing critical infrastructure support for the development of a new‑type power system.