Battery Monitoring and Sub Station Reliability - BTECH Inc

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Battery Monitoring and Sub Station ReliabilityBattery Monitoring and Sub Station Reliability

® History and PrincipalsHistory and Principals

BTECH BTECH Roots in Singer research begun in the 1980s 1st Stationary Battery Monitor (BVS) in 1991 1st Stationary Battery Monitor (BVS) in 1991

Privately owned All d i i i t h i l t All design, engineering, technical support,

services and manufacturing based in New Jersey Je sey

® History and PrincipalsHistory and Principals

P di ti l i ft Predicative analysis software Leading Indicator: Impedance

Ri / h lRise/ohms law Patented Methodology: (x) amps at

216 H DC B d illi lt 216 Hz over DC Bus, record milli volt response = Impedance

® Organizational CapabilitiesOrganizational Capabilities

Project Design Product Design and Engineering Software Engineeringg g Technical Support Field Services Field Services Remote Monitoring Product Manufacturing Product Manufacturing Sales

® Why Critical System Batteries Should Be Why Critical System Batteries Should Be MonitoredMonitored

Utility Industry Considerations for Battery Monitoring Smart Grid and Regulatory Efforts Require Real time

Access to the Sub-Station Battery Ability to detect open circuits

Centralized Data Access and Reporting ISO A dit C li ISO Audit Compliance

Standardization of DC Plant Management Consistent Evaluation Techniques

Improved DC Plant Asset Management Improved DC Plant Asset Management Elimination of Some Manual Testing Redundant Battery Strings may not be Necessary Personnel changes Personnel changes Many Customers have eliminated or pared DC

Plant Maintenance Staffs DC Plant Maintenance Expertise has Declined DC Plant Maintenance Expertise has Declined

® Industry Recommendations Industry Recommendations -- Regulatory PressureRegulatory Pressure

Regulations and Standards IEEE R d d P ti f M i t T ti d IEEE Recommended Practice for Maintenance, Testing, and

Replacement of Vented Lead-Acid Batteries for Stationary Applications,” published as IEEE Std 450* IEEE 450 – 2011, Elimination of Specific Gravity Testing,

Replaced with SOCReplaced with SOC

IEEE Recommended Practice for Maintenance, Testing, and Replacement of Valve regulated Lead-Acid Batteries for Stationar Applications ” p blished as IEEE Std 1188*Stationary Applications,” published as IEEE Std 1188*

IEEE Guide for Selection and Use of Battery Monitoring Equipment in Stationary Applications. Published as Std1491(Fi l i di )*Std1491(Final version pending)*

* These documents recommend ohmic measurement as a method for establishing the viability of a battery system

® Industry Recommendations Industry Recommendations -- Regulatory PressureRegulatory Pressure

REGULATIONS AND STANDARDS NERC Technical Paper on Protection System Reliability NERC Technical Paper on Protection System Reliability

NERC PRC-005-2

® NERC PRCNERC PRC--005005--22

Protection System Maintenance Program (PSMP) Verify Verify Monitor Test Inspect

Inspect

Calibrate

Station DC supply

Station DC supply(including station batteries, battery charges, and non-battery based dc supply)

Monitoring can be used to extend maintenance intervals Monitoring can be used to extend maintenance intervals

Source: Standard PRC-005-2 Protection System Maintenance

® NERC PRCNERC PRC--005005--22

NERC Recommended Monitoring Parameters High and Low Float Voltage High and Low Float Voltage Electrolyte Level Monitoring DC Ground Fault Proper Float Voltage Proper Float Voltage String Continuity Inter-cell Connections Internal Ohmic Values with Baselines Internal Ohmic Values with Baselines

(Initial Impedances) Compliance Eli i t ll t i t i t l Eliminates all or most maintenance intervals

Source: Standard PRC-005-2 Protection System Maintenance

® Why Critical System Batteries Should Be MonitoredWhy Critical System Batteries Should Be Monitored

Early Detection Is The Key To Improving Reliability

Theoretical vs Actual Failure Rate Theoretical vs Actual Failure Rate

2530354045

lure

s

2530354045

lure

s

05

101520

% F

ai

05

101520

% F

ai

1 2 3 4 5 6 7

Years

1 2 3 4 5 6 7

Years

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Battery Life Cycle Graph For VRLA BatteriesBattery Life Cycle Graph For VRLA Batteries

I d V C itI d V C itImpedance Vs. CapacityImpedance Vs. Capacity

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Examples Of Battery FailuresExamples Of Battery FailuresExamples Of Battery Failures

Found At

Examples Of Battery Failures

Found AtFound At

Customer Sites

Found At

Customer SitesCustomer SitesCustomer Sites

® BTECH RealBTECH Real--time Battery time Battery MonitoringMonitoring

Graphs of Real Time Data MonitoringMonitoring

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High and Low Float VoltageHigh and Low Float Voltage

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High and Low Float VoltageHigh and Low Float Voltage

High Float voltage – Over Charging

® Improper Improper Float ChargingFloat Charging

® String ContinuityString Continuity

® Inter Cell connectionsInter Cell connections

Impedance vs. Time: Effects of Re-Torquing

Service Technician R t U it

Impedance

Retorques Unit

Impedance 49 % above Initial Battery is deemed

defective and replaced

® Internal Ohmic Values Internal Ohmic Values

Initial Impedances – Ohmic/Voltage/Temperature Baselines

Green: Initial Read (Baseline) * Purple: Maintenance Limit (+40%) * Red: Critical Limit (+50)

Green: Ambient Temperature) * Cell temperatures* Min/Max Thresholds

® Example #3 Example #3 -- Unit 13Unit 13

Voltage vs. Time: Voltage Drops 10%

Unit 50 Impedance: 5.06 Milli-ohms (180.07% of String Initial Measurement) [2.81 Milli-ohms]p ( g ) [ ]


Impedance vs. Time: 120% in Two Weeks

Failure Within 2 Weeks

® Example #4 Example #4 –– Wet Cell Unit 213Wet Cell Unit 213

Voltage vs. Time: 10% Voltage Drop within 2 Weeks

® Example #4 Example #4 -- Wet Cell Unit 213Wet Cell Unit 213

Impedance vs. Time: No Change Recorded

Customer Replaced the Unit


Voltage vs. Time: DC Ground Fault

Unintentional Grounds


Temperature vs. Time: DC Ground Fault

Delta Temperature


System Voltage vs. Time: No Changes

® Example #7 Example #7 -- Unit ImpedancesUnit Impedances

Impedance vs. Unit Number

Notice the 5 Units With High Impedance

® Example #7 - Unit Voltages

Voltage vs. Unit Number During Discharge

These 5 Units Have the Lowest Voltage After Discharge

®Example # 8 Example # 8 –– Unit Failing During Unit Failing During

Discharge TestDischarge Test

Battery Discharge Test Results – JP Morgan 270 Park Ave NYC

® Example # 8 Example # 8 –– Unit Failing During Unit Failing During Discharge TestDischarge Test

Battery Discharge Test Results – Unit 234 Begins to Collapse

® Example # 8 Example # 8 –– Unit Failing During Unit Failing During Discharge TestDischarge Testgg

Battery Discharge Test Results – 9:35 Into Test


Battery Discharge Test Results – End of Test


Battery Discharge Test Results – Unit 234 Discharge Details

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TM

The Product

BTECH’s Fifth Generation Battery Monitoring SystemBTECH s Fifth Generation Battery Monitoring System

® Modular System ComponentsModular System Components

SCM-600 Control Module

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Voltage VM24i Module VM24i with CT

Real Time Monitoring• Cell Impedance • Ambient & Pilot Temperature• Cell Impedance • Ambient & Pilot Temperature

• String & System Current (Float/Charge/Discharge)• Cell & System Voltage (Float/Discharge)y g ( g )

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S5 System DiagramS5 System Diagram

System ComponentsSystem Components

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SCM 600 (Controller) 1 per UPS or Inverter System

VM 24 VM-24Up to 24 VSLs and 4 Ts per unit

CT – Current Transducer 1 per String

VSL – Voltage Sense Lead VSL Voltage Sense Lead

LCL – Load Control Lead

® Integration and CommunicationIntegration and Communication

Impedance emperature

Delta T Current (Float/Discharge )

® Battery TypesBattery Types

2 Volt Cells 2 Volt Cells

VLA, VRLAMonoblocks

4 6 8 12 16 Volts 4, 6, 8, 12, 16 Volts NiCad's 1.2 Volts

® S5 VRLA Stack InstallationS5 VRLA Stack InstallationTM

Unmanned Communications: 48V VRLA Stack

® S5 VRLA S5 VRLA Station Battery SystemStation Battery SystemTM

Switchgear: 10-12 Volt VRLA’s

® S5 SwitchgearS5 SwitchgearTM

125 Volt Switchgear: 93 Cell NiCad System

® S5 UPS 2 Volt Wet CellsS5 UPS 2 Volt Wet CellsTM

3-Phase UPS: 480 Volt, 240 Cell System

® S5 UPS 2 Volt VRLA StackS5 UPS 2 Volt VRLA StackTM


® S5 UPS VRLAS5 UPS VRLATM


® S5 UPS Wet Cell ApplicationS5 UPS Wet Cell ApplicationTM

(3) 3-Phase UPS: 480 Volt, 240 Cell Systems

® S5 Switchgear ApplicationS5 Switchgear ApplicationTM

(1) 125 Volt, 60 Cell Systems

® Typical Battery ArrangementsTypical Battery Arrangements

Open frame steel step racks 125V (60) 2 Volt Cells [VLA]


Battery Cubicle 48 Volt (23) 2 Volt Cells [VLA]


Battery Cubicle 48 Volt (4) 12 Volt Jars [VRLA]


Battery Cubicle 48 Volt (8) 6 Volt Jars [VRLA]

® S5 Standard Features and S5 Standard Features and NERC CompatibilityNERC Compatibility

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Measurement of key battery performance parametersfor trend analysis (failure prediction & prevention)

NERC CompatibilityNERC Compatibility

for trend analysis (failure prediction & prevention) Unit Impedance - Impedance is the leading indicator of

battery failure and finds bad batteries Plate cracking, warping, corrosion, post & strap

corrosion and cell dry-out are easily detectible Interconnect problems Initial measurements for each unit used for baselines

Unit Voltage – Can also be a leading indicator of failure Dendritic shortsDendritic shorts Thermal runaway

Ambient & Pilot Cell Temperatures – Problem prevention Environmental conditions Environmental conditions

® S5 S5 Real Time FunctionalityReal Time FunctionalityTM

® BTECH SoftwareBTECH SoftwareTM


BMS

® Centralized Alarm CollectionCentralized Alarm Collection

IEC 61850 DNP3

® Additional S5 System FeaturesAdditional S5 System FeaturesTM

Complete Isolation from the Battery String System is not powered by your batteries Completely invisible and passive to the battery system,

UPS/rectifier and load Factory Designed and Built Wiring Harnesses

Ensure system reliability Simple installation in 50% less time Simple installation in 50% less time Designed to meet site requirements

BTECH’s Unique Safety Fuse System All b tt l t Allows easy battery replacement Reduces battery replacement costs by up to 50%

® What is an Ohmic MeasurementWhat is an Ohmic Measurement

Oh i t i th Ohmic measurement - is the terminology used by the IEEE to describe the measurement of a battery describe the measurement of a battery cell’s internal resistance irrespective of the method used the method used Internal resistance - resistance to electrical

current created by reactance and ohmic yresistance

® Why Ohmic Measurements?Why Ohmic Measurements?

I d V C itImpedance Vs. Capacity

® How to Measure Internal ResistanceHow to Measure Internal Resistance

Th th l th b There are three values than can be used to define the internal resistance of a batterya battery DC resistance – measured by placing a

resistive load across the battery and resistive load across the battery and measuring the volts drop across each cell.


Impedance measured by either Impedance – measured by either establishing ac current flow through the battery or by injecting an ac signal into the y y j g gbattery. The resultant AC voltage developed across each cell measures b th th t d th DC i t both the reactance and the DC resistance of the cell

Conductance – the reciprocal of Conductance the reciprocal of impedance as it measures current flow rather than voltage drop


T i l L d A id M d l Typical Lead Acid Model


Rs Series resistance (metallic), posts, straps, plate to strap and intercell welds Acts as a simple resistor so strap, and intercell welds. Acts as a simple resistor so does not change with frequency.Rct - Charge transfer resistance (electrochemical)Cdl - Double layer capacitance (electrochemical), charge separation near the surface of the electrodes from ions close to the plate surface.from ions close to the plate surface.Zw - Warburg (Diffusional) impedance (electrochemical), non linear diffusion of ions in the

l t l telectrolyte.


I t l h i t ti i b d Internal ohmic testing is based on measuring the response of the cell to a voltage or current stimulus and relating voltage or current stimulus, and relating the response to an ohmic value.

The values of the components of the The values of the components of the model (Rs, Cdl, and Rct) correlate to the ohmic value calculated by the the ohmic value calculated by the instrument.


A hi h f t t i l ill t d A high frequency test signal will tend toward Rs - The Metallic Resistor

A l f t t i l ill t d A low frequency test signal will tend towards Rs + Rct + Zw

Th E ti B ttThe Entire Battery At high frequency Z ≈ Rs At low frequency Z ≈ Rs + Rct + Zw DC measurement tests tend toward RS

® BTECH’s Impedance MethodBTECH’s Impedance Method

BTECH Impedance Does Not Discharge Your Batteries

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S5 System DiagramS5 System Diagram

System ComponentsSystem Components

TM

SCM 600 (Controller) 1 per UPS or Inverter System

VM 24 VM-24Up to 24 VSLs and 4 Ts per unit

CT – Current Transducer 1 per String

VSL – Voltage Sense Lead VSL Voltage Sense Lead

LCL – Load Control Lead

® Effect of Testing on BatteriesEffect of Testing on Batteries

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Impedance vs. Voltage Response

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Benefits of Battery MonitoringBenefits of Battery MonitoringBenefits of Battery MonitoringBenefits of Battery Monitoring

NERC PRC-005 Better Compliance

Centralized Data Real Time Lower Maintenance Costs Superior Equipment Protection Reduction in Fines and Regulatory Reduction in Fines and Regulatory

Scrutiny

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Benefits of Battery MonitoringBenefits of Battery Monitoringy gy g

Critical system battery performance is assured Detection of major battery problems with enough

time to respond Reliability of backup power is increased y p p

Risk and revenue lost due to downtime are virtually eliminated

Battery management and maintenance costs Battery management and maintenance costs can be reduced significantly

Customer experience: Battery service life can be increased up to 100% when weak cells are replaced in time

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Benefits of Battery MonitoringBenefits of Battery Monitoring

System up time is increased Maintenance windows are shortened Batteries can be replaced proactively

Site acceptance testing is improved Battery data is captured with the BTECH System Additional equipment does not have to be rented Defective cells can be replaced before the

UPS/Battery system is put on line Overall Battery management is improved

Better overall evaluation and management of the total i iBattery Asset with Real time and Trended data

Improve continuity of service and system performance Better compliance with Industry and Local standards

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BTECH World Headquarters – Rockaway New Jersey USA

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BTECH Corporate CapabilitiesBTECH Corporate Capabilities

Complete Services: C l t D t ti d S b itt l Complete Documentation and Submittals Turn key project Management Engineering and Design Engineering and Design Installation Services Commissioning, Start-up and Training

Remote Monitoring and Maintenance Contracts

Technical Help Desk Support World Wide Service Network World Wide Service Network

® Field Service and SupportField Service and Support

BTECH Direct Service

Factory Authorized Pa tne sPartners

® BTECH BTECH –– Strategic CustomersStrategic Customers

Battery Monitoring and Sub Station Reliability - BTECH Inc

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