a short battery seminar presentdbted by - electric...
TRANSCRIPT
Selecting a Stationary Battery that Selecting a Stationary Battery that Provides Good Reliability and Keeps
Me Out of Trouble (or)Me Out of Trouble (or)Why All Cells are Not Created Equal
A Short Battery Seminar t d bpresented by
Chris SearlesNational Director of Marketing SalesNational Director of Marketing, Sales
and Business Development
BAE Batteries USA
What is a Stationary Battery?What is a Stationary Battery?
P ti• PropertiesA Dose of Physics
A Mixture of ChemistryA Bit of Metallurgy
And a Whole Lot of Electricity
All this resides in a container (or jar) or series of jarsAll this resides in a container (or jar) or series of jars connected to a power supply of some sort [rectifier or charger] and a load.
FunctionalityFunctionality
St ti B tt i t (2)• Stationary Batteries serve two (2) primary functions:
1. Provide Back-Up or Standby Power in case of a primary power failure.p y p
2. Provide Reserve Power [Energy Storage] for on-demand applications.g ] pp
Stationary Battery TypesStationary Battery Types
Lead AcidLead AcidNi-Cad
P ibl N Alt tiPossible New AlternativesLithium [Several Varieties]NAS [Sodium Sulfate]NAS [Sodium Sulfate]FlywheelsSupercapacitorsSupercapacitors
However today we will focus on the conventional lead-acid battery [used in Utility/Telecom/Critical UPS
li ti ]applications]
The Types of Grids Used with Lead Acid Batteries
Pure Lead
Manchex
L d A tiLead Antimony
Lead CalciumLead Calcium
Lead SeleniumLead Selenium
Grid AlloysGrid Alloys
P re Lead• Pure Lead
Advantages Disadvantagesg g
Long Service Life Low Power Density
H dl Hi h T t Li it d tHandles High Temperature Limited current throughputs
Not affected by O h
Soft “metal”Overcharges
Grid AlloysGrid Alloys
Lead Antimon• Lead AntimonyAdvantages Disadvantages
Excellent hardening agent Migration of Antimony + → -
Better grid density Increase in float current [can be dramatic near end of life]
Good current conductivity Increased water consumption
Resistant to damage from Shortened service life, discharge/recharge cycles [especially in float applications]
Thus, excellent cycling[good for deep cycle applications]
Higher float current prohibits use in VRLA’s[good for deep cycle applications]
Grid AlloysGrid Alloys
Lead Calci m• Lead CalciumAdvantages Disadvantages
Low float current Low number of cycles
Developed by Bell Labs (1935)
Manufacturing IssuesDifficulty mixing w/ lead( ) Difficulty mixing w/ leadDeposits at grain boundaries
Good constant load battery Variances with ICV’s [vpc]Good constant load battery Variances with ICV s [vpc]
Good choice for VRLA Platinum salt deposits lock after 8 yearsy
Grid AlloysGrid Alloys
Lead Seleni m• Lead SeleniumAdvantages Disadvantages
Combines best of both Calcium and Antimony Characteristics
Self discharge rate is faster than calcium
E ll t li biliti R hExcellent cycling abilities Recharge necessary every3-4 months if in storage
Tight regulation of the ICV’s
Predictable low-rise of float current over life
Good watering cyclesg y
What is a Lead Selenium Battery?What is a Lead Selenium Battery?
It is sed in VLA cells onl• It is used in VLA cells only
• It contains ≤ 3% antimonyThe IEC classifies a lead-selenium low-antimony battery as having ≤ 3% antimony≤ 3% antimony
• It also contains a trace of Selenium
• Until recently, best known in Europe
What Is a Lead Selenium Battery?What Is a Lead Selenium Battery?
VLA [Vented Lead Acid or Wet Cell]• VLA [Vented Lead Acid or Wet Cell]
• Lead Selenium vs. Lead Antimony– Low Antimony [≤3% per IEC ]– Medium Level Antimony [>3-6%]
Hi h L l A ti [ 6%]– High Level Antimony [>6%]
• Does it Make a Difference?We believe the answer is YES
But why? . . .
Lead Selenium BatteriesLead Selenium Batteries
Let’s Take a Look at a Few of theLet s Take a Look at a Few of theStrategic Advantages
of theof theLead Selenium/Low Antimony Battery
Batteries for Back-Up Power –Utilities/Telecom/Critical UPS
• Major Advantages vs Other Batteries• Major Advantages vs. Other Batteries– Performance and Unique Attributes rely on these 5
characteristics:1. Grid Alloy (s)
2. Post and Post Seal Construction
3 Jar to Cover Seal3. Jar to Cover Seal
4. Manufacturing Processes
5. Material Supplier QA Processes
– All 5 of these contribute to the performance characteristics of a “good” battery
– Let’s take a look at the Grid Alloy todayLet s take a look at the Grid Alloy today.
Batteries for Back-Up Power –Utiliti /T l /C iti l UPSUtilities/Telecom/Critical UPS
Th L d S l i /L A ti Ad tThe Lead Selenium/Low Antimony Advantage….– Advantages: Lead Selenium/Low Antimony vs. Lead
Calcium
• <3.0% Antimony still acts as a good hardening agent for lead. (BAE cells contain ≤ 1.6% of antimony)
• It supplies good grid density, conductivity and tensile strength
• Ugly antimony poisoning [migration] eliminated or• Ugly antimony poisoning [migration] eliminated or reduced
• Selenium acts as a grain refiner to inhibit positive grid and post corrosion
Batteries for Back-Up Power –pUtilities/Telecom/UPS
The Lead Selenium/Low Antimony Advantage….– Advantages: Lead Selenium/Low Antimony
vs Lead Calciumvs. Lead Calcium• Stability under float charge with predictable float current• Consistent cell voltages• Predictable float current• Superior cycling and deep discharge performance
– Order of Magnitude difference in cycling capability (1000 1200 cycles vs 80 200)(1000 – 1200 cycles vs. 80 – 200)
• Consistent performance and long-term life at full capacity
Float Currents - OPzS [Tubular] & OGi [Flat] Plates[ ] [ ]
100
Ah
IN m
A/1
00A
OPzS 2000
50
T A
T 2
,23V
I
OPzS 490
OPzS 200
OGi 1520FLAT PLATE VLALEAD SELENIUM
AT
CU
RR
ENT OGi 1520
OGi 800
OGi 480TUBULAR PLATE VLA
LEAD SELENIUM
00 5 10 15 20 25 30
FLO
A LEAD SELENIUM
OPERATIONAL LIFE AT 25°C
Uniform & Consistent Individual Cell Voltages [ICV‘s] expressed as VPC
• Cell 1 – 2 24 • Cell 13 – 2 23• Cell 1 – 2.24• Cell 2 – 2.23• Cell 3 – 2.23• Cell 4 2 22
• Cell 13 – 2.23• Cell 14 – 2.23• Cell 15 – 2.22• Cell 16 2 24• Cell 4 – 2.22
• Cell 5 – 2.24• Cell 6 – 2.25• Cell 7 2 23
• Cell 16 – 2.24• Cell 17 – 2.24• Cell 18 – 2.25• Cell 19 2 23• Cell 7 – 2.23
• Cell 8 – 2.23• Cell 9 – 2.21• Cell 10 2 23
• Cell 19 – 2.23• Cell 20 – 2.22• Cell 21 – 2.21• Cell 22 2 23• Cell 10 – 2.23
• Cell 11 – 2.23• Cell 12 – 2.24
• Cell 22 – 2.23• Cell 23 – 2.23• Cell 24 – 2.23
Note: this is a representation. Actual individual cell voltages will be within the +/- tolerance as noted in the manufacturer’s technical documentation.
OPzS IEC 60 896-1 CYCLE TEST (Test Data for a BAE OPzS)(Test Data for a BAE OPzS)
C10120
80
100
60
OPzS
20
40
IEC 60 896-1 6 OPzS 490 AhDischarge 3h with 84A (app. 75% DOD C4)Recharge 21h with 2.40V, initially 84A
OPzS>1500 cycles
Dec 1994 Cycles Jun 1999
00 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
J i 1999
EQUIVALENT LIFE TIMES AT VARIOUS TEMPERATURES Based on the ARRHENIUS Equation Method
50
Based on the ARRHENIUS Equation Method(Again, based on Accelerated Life Testing for BAE Models)
40
rs
(BAE) OPzS
(BAE) OPzV
42.6/27.5 yrs
34.8/22.5 yrs
20
30
me
/ y
ear
years at 20°Cyears at 25°Cyears at 30°C
33.0/21.3 yrs– (BAE) OGi
10
20
life
tim
yyears at 35°C
related to an activation energy of
00 100 200 300 400 500 600
activation energy of IEEE 535-1986
float charge at 62,8°C / days
Batteries for Back-Up Power –pUtilities/Telecom/Critical UPS
The Lead Selenium/Low Antimony Advantage….y g– Summary: Lead Selenium/Low Antimony vs. Lead
Antimony or Lead Calcium• Stability under float chargeStability under float charge• Consistent cell voltages• Predictable float current• Superior cycling and deep discharge performancep y g p g p
– Order of Magnitude difference in cycling capability (1000 – 1200 cycles vs. 80 – 200)
• Consistent performance and long-term life at full capacity
– One Caution:• Batteries in storage should be recharged every 3 – 4
months
Batteries for Back-Up Power –pUtilities/Telecom/Critical UPS
Why Are Different Manufacturers providingManufacturers providing
OPzS or OGi cells?OPzS = Tubular PlateOGi = Flat PlateOGi = Flat PlateOriginally per German DIN StandardsNow rolled into IEC BodyNow rolled into IEC Body
A Careful Look at the Tubular Plate CellA Careful Look at the Tubular Plate Cell
Wh t Gi th T b l Pl t C ll ItWhat Gives the Tubular Plate Cell Its Unique Advantages
THE MAKEUP OF THE TUBULAR PLATETHE MAKEUP OF THE TUBULAR PLATE
Expansion of the positive active mass is restricted by the tubes.
The tubes consist of woven polyester with high burst strengthThe tubes consist of woven polyester with high burst strength.
VOLUME INCREASE DURING DISCHARGEVOLUME INCREASE DURING DISCHARGE
density mole weight mole volumePb 11 34 kg/l 207 2 g 18 3 cm³Pb 11.34 kg/l 207.2 g 18.3 cm
β - PbO2 9.30 kg/l 239.2 g 25.7 cm³PbSO4 6.29 kg/l 303.3 g 48.2 cm³
48 2 / 25 7 1 88 48 2 / 18 3 2 6348.2 / 25.7 = 1.88
PbO2 PbSO4 Pb
48.2 / 18.3 = 2.63
CONSEQUENCES OF VOLUME INCREASEOF THE POSITIVE PLATE
Expansion of the active material
1 Reduces the connection between grid and 1. Reduces the connection between grid and pos. mass (PCL1)Critical connection between lead and lead dioxide: A Pb O barrier has to be avoided.
2. Reduces the connection between pos. mass particles (PCL 2)
PCL…. Premature capacity loss
Two Processes for Filling Tubular Platesg
1 Wet Filling1. Wet Filling
2 Dry Filling is the better method2. Dry Filling – is the better method
Let’s see why!
Advantages of Dry FillingAdvantages of Dry Filling
1. When a manufacturer uses a Red Lead Oxide Powder which is >98% pure i i l d ll i f ti b t [W l d l d f tivirgin lead all imperfections are absent. [We use recycled lead for motive
and automotive batteries]
2. Wet filling does not usually use this high percent grade of Lead Oxide; therefore, in most cases, a higher specific gravity is used to compensate for
i hi h ib h b lifcapacity which contributes to a shorter battery life.
3. When a manufacturer uses a dry-filled, controlled vibration process, this ensures that each tube is filled completely, uniformly and packed evenly. Wet filling uses a pressure system that packs the Lead Oxide tight with an
f fincreased likelihood of forming cracks in the gauntlet.
4. When a manufacturer uses a polyester woven gauntlet for their stationary batteries these gauntlets will have a much higher burst resistance than fiber gauntlets.
UNIQUE ADVANTAGE RESTATED:During the expansion/contraction of the lead during discharge/recharge, the gauntlet holds the active material tight against the lead – less or no shedding; maintains full capacity overagainst the lead – less or no shedding; maintains full capacity over service life.
TUBULAR PLATE CELLS (Cont’d)( )
• Corrosion- Resistant Lead Selenium Grid and Woven Polyester Gauntlet
• Filled Tubes with Grid, and Unfilled Tubes
TUBULAR PLATE CELLS (Cont’d)( )
• Filling station of tubular plate manufacturing
• Tubes are filled and capped, then, each plate is weighed
Now A Careful Look at the Flat Plate CellNow A Careful Look at the Flat Plate Cell
What About the Flat-Plate Cell –Does It Provide Any Unique y q
Advantages
TANK Formation of Positive and Negative Platesg
A very few manufacturers tank form their plates vs. jar formation of individual cells.
Note: TANK FORMING ensures consistent quality of all plates [versus jar forming where each jar is “cured”unto itself]unto itself]
.
This Poses a Question when it Comes to Lead-Selenium Batteries
Which is better to use in my Applicationpp
Batteries for Back-Up Power –Utility/Telecom/UPS
• Tubular [OPzS] vs. Flat Plate [OGi][ ] [ ]– Tubular (OPzS) [excellent for telecom & power generation]
• While it’s Long Duration Battery rates are excellent, it’s 1-min rates compare favorably w/ General Purpose Lead-Calcium cells
[Excellent for Float Applications w/ >1hr -100 hr duration]
• Web Sock aids compression
– Flat Plate (OGi) [excellent for UPS & Switchgear]V G d G l P B• Very Good General Purpose Battery[High 1-min, 15-min &1-hour rates]
• Good Long Duration Rates in the lower Ah sizes[C8/C10 rates are good as well]
Batteries for Back-Up Power –Utility/Telecom/UPS
525600
Discharge Rate Comparison [200Ah to 1.75 vpc]
Model B
75150225300375450
AmpsModel B OPzS
Model B OGi
1 Min 1Hr 3 Hr 8Hr 12hrModel B OPzS 236.6 111.3 51.4 24.6 18.9Model B OGi 541.8 126 55.3 25.4 18.6Model E Calcium 288 108 51 4 25 17 6
0 OGi
Model E Calcium
M d l CModel E Calcium 288 108 51.4 25 17.6Model C Calcium 287.4 108.4 51.4 25 0
Time
Model C Calcium
Batteries for Back-Up Power –Utility/Telecom/UPS
Discharge Rate Comparison [to 1 75 vpc]
900
1200
Discharge Rate Comparison [to 1.75 vpc]
M d l B OP S
0
300
600AmpsModel B OPzS 1200
Model B OGi 1200
15 Min
1 Hr
3 Hr 5Hr 8
HrModel B OPzS 1200 771 599 324 234 168Model B OGi 1200 1323 697 304 204 141
0Model G (1220)
Model L (1200)Model B OGi 1200 1323 697 304 204 141Model G (1220) 672 556 316 211 152Model L (1200) 966 604 322 150
Time
Model L (1200)
Time
A Quick Word About Post and Post-Seal ConstructionA Quick Word About Post and Post-Seal Construction
Aren’t Leaking Cells and Cracked Jar Covers a Fairly Common y
Problem
BAE – POST/BUSHINGBAE POST/BUSHING
Panzer Type Pole Panzer Type Pole
• Rugged construction
• Rubber rings allow slidingRubber rings allow sliding[100% acid – tight]
Special Manufacturing Process
• Machined lead pole with brass insert
• Injection molded ABS plastic• Injection molded ABS plastic
• Red primer for good adhesion
• Notches act as barrier “dams” to limit “acid creep”
Some Cautionary NotesSome Cautionary Notes
Does Receiving and Installation Procedures really have an Impact on y p
Service Life
A W d Ab t I t ll tA Word About Installation1. Biggest problem occurs w/ shippinggg p pp g
1) Check for damage at receiving2) Must report concealed damage w/i 48 hrs for
FOB Destination shipments3) Unfortunately, it is the users cost after that
point2. Checklist against manufacturer’s g
instructions1) Recommend voltage, S. G. and temperature
recording2) Check torque settings w/ calibrated torque
wrench3) Baseline ohmic measurement
t titesting
A W d Ab t M tA Word About Maintenance1. We recommend following IEEE 450 Guidelines and
h f ’ i d ithe manufacturer’s operations and maintenance manual as priority.
2. With NERC requirements now entering the picture (f l t i tiliti ) th i i i t t(for electric utilities), the issue is consistency, true reliability and ensuring compliance.
3. The only way to determine true capacity is thru it t ti IEEE 450capacity testing – IEEE 450
1) Performance testing2) Service testing (based on actual duty cycle)3) Modified performance testing3) Modified performance testing
4. A brief word about Battery Monitoring