The COST of Battery Maintenance Can you afford to be without it? 1 Why Batteries are Needed ? § Electric generating stations and substations for protection and control of switches/breakers and relays § Telephone companies to support phone service § Back up of critical power dependant equipment (life support systems, business information systems, data centres) § Industrial applications for protection and control § Industrial process control Failure is not an Option 2 Battery Types n Primary Cells – These are non-rechargeable batteries. These include the standard Alkaline battery and Lithium batteries. n Secondary Cells – These are the rechargeable batteries. These include lead acid batteries, NiCD as well as Lithium Ion. 3 Secondary Batteries n Cyclic Batteries – These are batteries that are used on a regular basis. The most common of these is automotive batteries or portable battery operated devices. n Standby Batteries – These are batteries that remain charged but are not used unless needed. • Sub-stations (Relays) • Telecom (Communication) • Data Centers (UPS) 4 Basic Types n Lead-acid • Flooded • Sealed n Nickel-cadmium • Flooded • Sealed n Other chemistries • Li Ion • NiMH 5 Common Failure Modes 6 Positive Grid Corrosion n Normal failure mode in flooded lead-acid and VRLA batteries n Lead alloy turns to lead oxide. n Plates grow n Designed into batteries n Acceleration due to: • Overcharging • Excessive cycling • Excessive temperature n Increase in internal impedance 7 Sediment (Shedding) n Sloughing off of active material from plates into white lead sulfate. n Small amount is normal n Can cause plate shorts n Due to overcharging and excessive cycling. n sulfation slough off - undercharging n Seen in flooded batteries, most common in UPS systems. 8 Plate Sulfation Active plate material turns to lead sulfate. Lead Sulfate = Inactive material Occurs in both Flooded and VRLA batteries Natural process during discharge. Recharging reverses the process. Undercharging causes sulfate crystals to form on the plate surfaces. n Not enough current flowing to keep the battery fully charged. n n n n n n 9 Plate Sulfation n Sulfate crystals that harden over a long period of time. n These will not go back in solution when proper voltage is applied. n Decreases total active material/capacity n Result in a permanent loss of capacity. n Increase in internal impedance 10 Shorts n Shorts can occur in both Flooded and VRLA cells. n Hard sorts are typically caused by paste lumps pushing through the matte and shorting out to the adjacent (opposite polarity) plate. n Soft shorts, on the other hand, are caused by deep discharges. n When the specific gravity of the acid gets too low, the lead will dissolve into it. Since the liquid (and the dissolved lead) are immobilized by the glass matte, when the battery is recharged, the lead comes out of solution forming dendrites inside the matte. n In some cases, the lead dendrites short through the matte to the other plate. 11 Dry-Out (Loss of Compression) n VRLA batteries only n Dry-out is a phenomenon that occurs due to excessive heat, over charging can cause elevated internal temperatures as well as high ambient (room) temperatures. n At elevated internal temperatures, the sealed cells will vent through the PRV. n When sufficient electrolyte is vented, the glass matte no longer is in contact with the plates, thus increasing the internal impedance and reducing battery capacity. 12 Thermal Run-away n Thermal run-away is when a battery internal components melt-down in a self-sustaining reaction. n Failure mode VRLA batteries n Can end in complete and catastrophic failure n Primarily due to oxygen recombination cycle n Thermal run-away is relatively easy to avoid, simply by using temperature-compensated chargers and properly ventilating the battery room/cabinet. n Temperature-compensated chargers reduce the charge current as the temperature increases. 13 Thermal Run-away n Flooded cell allows gas to escape n VRLA recombines oxygen and forms water n Reaction produces heat n Due to: • • • • Overcharging High ambient Low air flow High float voltage n Heating is a function of the square of the current 14 Separator Deterioration n Separator Deterioration n Effects Ni-Cd cells n This will occur in all NiCd batteries as they age. n The separator breaks down allowing the plates (electrodes) to touch and short out the battery. 15 Carbonation n Carbonation occurs as part of the aging process in NiCD cells. n The potassium hydroxide (KOH) electrolyte enters into chemical combination with atmospheric carbon dioxide (CO2) and forms potassium carbonate (K2CO3). n This removes the KOH ions from the electrolyte and makes the cell less able to conduct electricity. n The decrease in electrolyte conductivity makes the cell reach a lower voltage much more quickly under discharge. n As such, electrolyte carbonation appears to the cell's user as diminished capacity. n This can be reversed by exchanging the electrolyte. 16 Loose Connections n Frequent Problem all battery types n Easily found with resistance measurement n High resistance = elevated temperature = higher resistance n When serving load high temperatures can melt lead posts Watts Lost = (Current)2 (Resistance) 17 Why maintain batteries? Several things can happen when batteries are left un-monitored: • Battery terminals can become corroded • Ventilation systems can fail • Battery housing can build up pressure and crack • Batteries will not deliver when needed 18 Bad things can happen when Batteries do not function properly 20MW Generator Damage after DC System Failure – Machine lost DC Oil Pumps and Breaker Failed to trip. Unit motorized for 45 minutes. Shaft sheared in 3 places. Repairs exceeded $3M and 6 months downtime. 19 Battery Explosion § Internal generated sparks and extreme temperature rise caused by high-resistance internal parts, can lead to dangerous cell explosion. § Damage: Battery explosion damaged Battery Room and caused hazardous battery fumes to infiltrate the adjacent Switchgear room causing further damage. 20 Battery Explosion Results can be Catastrophic This Battery room lost ventilation and the Hydrogen Monitors were in Alarm Mode for 3 days prior to the explosion, but nobody paid attention to them. The resulting explosion caused a 400 sq ft hole in the roof. 21 Well Maintained & Clean Battery Installation 22 Poorly Maintained & Corroded Battery Terminal 23 Battery Maintenance 24 Intro n No single test tells the whole story n Determine condition n Where condition is headed n How fast n Don’t find out during an outage that your battery failed n Gather as much test data as possible 25 Test Methods n Visual Inspection n Float Voltage n Float Current n Ripple Current n Specific Gravity n Temperature n Discharge Testing n Ohmic Testing n Strap Resistance 26 Visual Inspection n n n n n n n Check entire system Battery Electrolyte Level (Flooded Batteries) Ventilation system, floor & room clean Battery support system Check batteries for cracks, leaks and deformation Strap corrosion Record information • Visual inspection will locate such things as cracks, leaks and corrosion can be found before they become catastrophic failures. However, visual inspection tells us nothing about the strings State of Charge (SOC), capacity or State of Health (SOH). 27 Float Voltage n Measure across each cell n Measure at posts n During float conditions n Not during discharge or recharge n Compare float voltage to manufacturers recommendation 28 Float Voltage n Applied voltage to cell from charger n Different voltages for different chemistries n Low float voltage > not fully charging • Can’t supply full capacity • Plate Sulfation n High float voltage > Over charging • cooks the battery • higher temperature • Grid corrosion • Thermal runaway • Dry-out ■ Float Voltage will tells us if something is wrong but it will not tells us anything about SOC, Capacity or SOH. 29 Float Current n Kirchhoff current law n Measure anywhere in the string n Usually low value n Measure during float conditions n Not during discharge or recharge n Increase in float current precursor to Thermal Runaway VRLA 30 Float Current n Current through each cell • Interaction between float voltage and internal resistance n Supplied by charger n Electrochemical process reversed • Lead sulfate on plates converted to sulfuric acid and active material n High float current precursor to thermal runaway • Short circuits • Ground faults • High float voltages ■ Float Current will tells us if something is wrong but it will not tells us anything about SOC, Capacity or SOH. 31 Ripple Current n n n n By-product of charging system Design, quality and age dictate Internal heating of battery and overcharging No more than 5A for every 100Ah 32 Specific Gravity n Ratio of density of liquid with respect to density of water n How much sulfate is in electrolyte – lead acid n Gives SOC but not Capacity or SOH. n Density is temperature dependent • So Specific Gravity is also Density = Mass Volume 33 Temperature n High temp = short life n Low temp = low capacity possible damage n 10 °C rise = ½ life 120 30 110 25 100 20 90 15 80 10 70 Battery Life (yrs.) Capacity (%) Temperature Effects 5 60 50 0 47 62 77 92 107 Temperature (F) % Capacity Life (yrs.) 34 Discharge Testing n Single absolute test n Complexity & cost n Acceptance Test • Beginning of life based on design capacity n Performance Test • After two or three years when new then every five years • Based on design capacity also n Service Test • As needed to determine if battery will support existing load n Discharge Testing is the only test that will determine the capacity of the string, but not necessarily the SOH. Volts per Cell Partial Load Test 2.3 2.1 1.9 1.7 1.5 0 5 10 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 Time (min) Passes Better Failure 35 Ohmic Test n Impedance, Conductance & Resistance n IEEE uses term ohmic n DC based on V=IR : AC based on V=IZ n As a battery ages it may corrode, sulfate, dry-out or suffer a host of other effects based on maintenance, chemistry and usage. All of these effects cause a chemical change in the battery; which in turn causes a change in the batteries internal impedance / resistance. n Ohmic testing measures the SOH. 36 Inter-Cell Resistance n If the torque not sufficient this will cause a higher resistance causing a voltage drop that causes heat. n Measure across strap • Not on Strap • On Post 37 Inter-Cell Resistance n Must include all resistance between posts n Multiple straps – Multiple measurements n Low resistance ohm meter or device designed for batteries 38 Ohmic Testing 39 Ohmic Testing n Ohmic battery testing is a method of testing batteries that compliments discharge testing. Discharge testing is an absolute way of measuring battery capacity. Ohmic testing is a relative measurement used to supplement discharge testing, Discharge testing is expensive, time consuming and can reduce the overall total life of the battery string. 40 Ohmic Testing Ohmic testing; which includes resistive testing, impedance testing and conductance testing is a relative test. It compares an ohmic measurement to a previous ohmic measurement as well as the average ohmic measurement of the string. When performing ohmic measurement a baseline should be established. Ascending Impedance with Corresponding End Voltage 2.5 Impedance (mOhms) & End Voltage n 2.25 2 1.75 1.5 1.25 1 0.75 0.5 0.25 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Imp 0.27 0.27 0.27 0.56 0.61 0.63 0.65 0.68 0.71 0.72 0.74 0.75 0.79 0.8 0.82 0.84 0.89 0.9 0.91 0.94 0.96 1.17 1.19 2.1 End V 2.03 2.04 2.03 1.98 1.97 1.94 1.9 1.91 1.88 1.89 1.9 1.89 1.89 1.84 1.82 1.84 1.81 1.84 1.8 1.73 1.82 1.74 1.33 0.1 Cell # 11 15 16 3 18 22 13 24 10 14 23 20 5 9 6 4 21 8 1 12 2 17 7 19 41 Type of Ohmic Testing n Resistance – Measures only the resistive value of a battery, The battery also has capacitive and inductive values as well. n Conductance – (Actually Admittance) This is the reciprocal of impedance. n Impedance Testing – Measures the resistive, capacitive and inductive qualities of the battery. n NOTE: Ohmic testing is a relative test NOT an absolute test. We do not test against an absolute value. We test and compare that data to a previous test result. n Repeatability is KEY. 42 Impedance Test n Impedance testing has a distinct advantage over resistive type testing. When we look at a schematic representation of a battery there are more than just resistive components to that battery. There are also capacitive and inductive characteristics. n This means that impedance testing will be able to detect certain problems that resistive measurements can miss; these include negative lug rot as well as negative plate corrosion. These failures will show themselves as changes in inductance and capacitance, not in resistance. In addition many chemical changes in a battery will be seen as impedance changes before they are seen as resistive changes. 43 Impedance Test n Provides SOH rather than just SOC n As the battery ages and sulfates the impedance of the battery will increase as the capacitance decreases. Ascending Impedance with Corresponding End Voltage Impedance (mOhms) & End Voltage 2.5 2.25 2 1.75 1.5 1.25 1 0.75 0.5 0.25 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Imp 0.27 0.27 0.27 0.56 0.61 0.63 0.65 0.68 0.71 0.72 0.74 0.75 0.79 0.8 0.82 0.84 0.89 0.9 0.91 0.94 0.96 1.17 1.19 2.1 End V 2.03 2.04 2.03 1.98 1.97 1.94 1.9 1.91 1.88 1.89 1.9 1.89 1.89 1.84 1.82 1.84 1.81 1.84 1.8 1.73 1.82 1.74 1.33 0.1 Cell # 11 15 16 3 18 22 13 24 10 14 23 20 5 9 6 4 21 8 1 12 2 17 7 19 44 Discharge Testing n Discharge Testing is a direct measurement of a battery strings capacity. n It is a long test that requires the string to be taken off line most times. n Why perform discharge testing? n IEEE requires it and it is the only true measurement of capacity. n Temperature must be taken into account during testing. 45 Discharge Testing n Calculating a Batteries Capacity from a Discharge Test n Use the equation below to determine the battery or cell/unit capacity for a discharge test that runs 1 h or longer. • • • • C tA tS KT Is the % capacity at 25 ºC is the actual time of the discharge test. is the calculated time of the discharge test. is a correction factor for the cell temperature. 46 Discharge Testing n This table is based on flooded lead acid batteries with a nominal 1.215 specific gravity. For cells with other specific gravities or chemistries refer to the manufacturer. 47 Conclusions n Regular Battery Maintenance is essential for the safe and reliable operation of a DC System n Maintenance needs to include Load Testing and Impedance Testing. n Online Load Testing is an option for determining battery capacity when offline is not practical. n Impedance Testing is used to compliment discharge testing and is the only way to determine battery state of health. 48 Thank you 49