Battery Monitoring and Sub Station Reliability - BTECH Inc
Transcript of Battery Monitoring and Sub Station Reliability - BTECH Inc
®
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
®
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
®
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
®
High and Low Float VoltageHigh and Low Float Voltage
®
High and Low Float VoltageHigh and Low Float Voltage
High Float voltage – Over Charging
® Improper Improper Float ChargingFloat 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 ) [ ]
® Example #3 Example #3 -- Unit 13Unit 13
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
® Example #6 Example #6 -- Unit 42Unit 42
Voltage vs. Time: DC Ground Fault
Unintentional Grounds
® Example #6 Example #6 -- Unit 42Unit 42
Temperature vs. Time: DC Ground Fault
Delta Temperature
® Example #6 Example #6 -- Unit 42Unit 42
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
® Example # 8 Example # 8 –– Unit Failing During Unit Failing During Discharge TestDischarge Testgg
Battery Discharge Test Results – End of Test
® Example # 8 Example # 8 –– Unit Failing During Unit Failing During Discharge TestDischarge Testgg
Battery Discharge Test Results – Unit 234 Discharge Details
®
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
TM
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 )
®
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
® 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
3-Phase UPS: 480 Volt, 240 Cell System
® S5 UPS VRLAS5 UPS VRLATM
3-Phase UPS: 480 Volt, 240 Cell System
® 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]
® Typical Battery ArrangementsTypical Battery Arrangements
Battery Cubicle 48 Volt (23) 2 Volt Cells [VLA]
® Typical Battery ArrangementsTypical Battery Arrangements
Battery Cubicle 48 Volt (4) 12 Volt Jars [VRLA]
® Typical Battery ArrangementsTypical Battery Arrangements
Battery Cubicle 48 Volt (8) 6 Volt Jars [VRLA]
® S5 Standard Features and S5 Standard Features and NERC CompatibilityNERC Compatibility
TM
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
® BTECH SoftwareBTECH SoftwareTM
® Integration and CommunicationIntegration and Communication
BMS
® Centralized Alarm CollectionCentralized Alarm Collection
IEC 61850 DNP3
® Integration and CommunicationIntegration and Communication
® 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.
® How to Measure Internal ResistanceHow to Measure Internal Resistance
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
® How to Measure Internal ResistanceHow to Measure Internal Resistance
T i l L d A id M d l Typical Lead Acid Model
® How to Measure Internal ResistanceHow to Measure Internal Resistance
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.
® How to Measure Internal ResistanceHow to Measure Internal Resistance
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.
® How to Measure Internal ResistanceHow to Measure Internal Resistance
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
®
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
TM
Impedance vs. Voltage Response
®
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
®
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
®
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
®
BTECH World Headquarters – Rockaway New Jersey USA
®
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