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Successfully Implementing Grid-Supportive Large-Scale Battery Storage

7/7/2025

Pioneering spirit, a steep learning curve, and plenty of perseverance: That’s how the Schaper Group independently built and now operates a grid-supportive large-scale battery storage system at a substation in Herford, Germany. The result is a blueprint for future projects of this scale. For all control, regulation, and data technology, the company relies on WAGO.

At a Glance:

Enhanced power supply reliability through flexible grid stabilization
2,600 lithium-ion modules housed in five containers, with a total capacity of nearly 21 MWh. Expansion to 41.6 MWh planned
WAGO technology used: PFC200 Controller, Edge Controller and Edge Devices, power supplies

The “Schaper Grid Energy Storage”

Key facts about the lithium-ion-based large-scale battery storage system: a total of 2,600 battery modules distributed across five 40-foot containers, each housing 520 modules, with a combined capacity of 20,800 kilowatt-hours. Connected to one of ten substations in the city of Herford, the system can supply electricity to around 900 households. Total investment: €15 million. Official project name: “Schaper Grid Energy Storage Füllkamp.”

Since September 10, 2024, the grid-supportive battery storage system has been active in the energy market. “We offer primary and secondary control reserve services as well as energy trading through a marketing partner,” explains Sven Oberwemmer, the technical lead behind Schaper Group’s largest storage project to date. As senior product manager for energy systems, he sees strong momentum in the market: “This is a wave that will hit us over the next five years. To drive the energy transition forward, we’ll need a wide range of grid-supportive battery storage systems operating across different control reserve levels and trading platforms.”

This is a wave that will hit us over the next five years.

Sven Oberwemmer | Chief Product Manager at Schaper

Pioneering Excellence through Deep Vertical Integration

No doubt — the project was and remains technically demanding. “But we enjoy tackling complex challenges,” says Sven Oberwemmer with a smile. What made it possible? The company’s high level of vertical integration. “We aim to be independent of manufacturers and operate autonomously,” he adds. That’s a point of pride at the Schaper Group: Reflecting on the project, Oberwemmer concludes: “We’ve truly done pioneering work here — especially beyond the technical aspects.”

The Schaper Grid Energy Storage System and Its Technology in Pictures

The “Schaper Grid Energy Storage” is directly connected to the nearby Westfalen Weser Netz substation. Photo: Katharina Uschmann

From the outside, unassuming — inside, powerful: The “Schaper Grid Energy Storage” delivers a total capacity of 20,800 kilowatt-hours. Photo: Katharina Uschmann

The facility houses five 40-foot containers — three of which are visible here. Photo: Katharina Uschmann

Pioneering spirit, a steep learning curve, and plenty of perseverance: Sven Oberwemmer (rear) and Eduard Neumann walk through one of the five containers. Photo: Katharina Uschmann

Not a data center, but a battery container: Behind closed doors, the battery modules glow green. Photo: Katharina Uschmann

The control center of the battery storage system: Built entirely in-house using the WAGO PFC200 Controller, WAGO Edge Controller, and power supplies, the team created a highly available control, regulation, and data system. Photo: Katharina Uschmann

WAGO technology bridges automation and IT — securely and seamlessly. Photo: Katharina Uschmann

WAGO's power supplies ensure reliable and efficient power distribution in the control cabinet. Photo: Katharina Uschmann

WAGO Edge Devices in action: The WAGO Edge Computer (top center) offers high processing power and storage, while the WAGO Edge Controller (top right) provides extensive interface options. Photo: Katharina Uschmann

Energy management in real time: The system reads and visualizes data every second. Photo: Katharina Uschmann

Financing, Permits, and Certification

The plan for the grid-supportive large-scale battery storage system was already in place by spring 2022. The plan for the grid-supportive large-scale battery storage system was already in place by spring 2022. Possibly. In the end, funding was secured through a pool of investors from the East Westphalia-Lippe region. The grid operator Westfalen Weser gave the green light in November and December 2022. The permitting process proved more difficult. “That cost us three-quarters of a year,” recalls Sven Oberwemmer. Battery storage systems housed in buildings were unfamiliar territory for the authorities. Noise and fire protection, in particular, were major concerns. “We consulted the fire department about the required extinguishing system, conducted fire tests, and filled containers with smoke. Now, if you go by wind speed, there’s a real storm blowing through the container.”

Grid-Supportive Battery Storage: Construction Phase

Construction began in August 2023. “We had everything installed and up and running within three months.” The goal was clear: be online by January 1, 2024. It was a major effort — including 30 hours of manual capacity testing over the Christmas holidays. “It was a very demanding time,” says the project manager. “Our learning curve was steep. Certifying a large-scale storage system is far more complex than anything we’ve done before.” Especially for the medium-voltage connection in compliance with standards, Sven Oberwemmer wanted to minimize his team’s burden. “And we did, with WAGO’s compact and flexible solution.”

WAGO Technology Connects PLCs with the IT World

“We chose WAGO because the company is a leader in energy technology and was among the first to offer a grid connection controller compliant with VDE-AR-N 4110,” explains Eduard Neumann, software developer for energy systems at Schaper. “Thanks to WAGO’s grid interface, we can easily connect to many grid operators.” That’s why he describes the commissioning of the first remote control unit at the Herford substation — via IEC 60870-5-101 — as “relatively seamless.”

With WAGO, we can securely and easily connect programmable logic controllers to the IT world.

Eduard Neumann | Software Developer at Schaper

Energy Management: A Stream of Insightful Data

Leveraging the WAGO PFC200 Controller, Edge Controller, and power supplies, the team independently developed a highly available system for control, automation, and data management. Values are read and visualized every second. “It’s a flood of data — but one that’s incredibly insightful. It’s a real gain in knowledge and essential for ensuring battery lifetime guarantees.” The SCADA integration for the energy management system, based on Linux®, was also implemented in-house by the Schaper team. “With WAGO, we can securely and easily connect programmable logic controllers to the IT world,” summarizes software developer Eduard Neumann.

Schaper and WAGO: A Strong East Westphalian Connection

The connection to WAGO is not only technical, but also professional and personal. “We have direct contacts we know well and who respond quickly,” says the team. And of course, there’s the regional bond: “We’re connected through East Westphalia.”

A Blueprint for Future Projects — With Room for New Talent

The grid-supportive battery storage system has become a blueprint for upcoming regional and national projects. That’s why Sven Oberwemmer is always on the lookout for motivated professionals eager to contribute to exciting projects at the general contractor Schaper. “We’re always happy to strengthen our team — both professionally and personally.” The next EPC project in support of the energy transition is already in the pipeline: “We’ll soon be making the landfill site in Lübeck energy self-sufficient,” he reveals. The experience gained from the “Grid Energy Storage” project will undoubtedly prove valuable.

Konstantinos Chatzis, Sales Manager Industry

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