Fundamentals, Selection and Sizing of Standby Batteries
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Transcript of Fundamentals, Selection and Sizing of Standby Batteries
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Fundamentals, Selection and Sizing
of
Standby Storage Batteries
4 February 2010
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4 February 2010
Standby Batteries In Generating Stations & Substations
Application :
-- Unit Battery
Substation Battery
PLCC
24/26v C & I Battery
UPS Battery
Battery for VHF set
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4 February 2010
Battery Is Considered To Be The HEART Of The
Power Plant Battery provides the ultimate and final DC back-up for
operating emergency equipment which power the turbogenerators (viz. emergency oil pumps etc.)
DC power for operation of all switchgear, protectionrelays, indicating lamps and facia
Power for emergency lighting within the generatingstation building
Uninterrupted power for controlling C & I equipment and
associated ups systems Power for vital communication equipment (plcc),
essential for re-synchronising the unit with the grid orfor reviving the grid in the case of a major grid failure
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4 February 2010
What If The Battery Fails In An Emergency
Unit Battery
The emergency oil pump will not operate which may
lead to the seizure of rotor bearings
Loss of hundreds of crores of rupees towards repairingthe rotor and generation revenue loss while the unit is
out of commission
Switchgear associated with generator may not trip
which can lead to generating transformer damage
Failure of instrumentation and control
Total darkness in the powerhouse
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4 February 2010
What If The Battery Fails In An Emergency (contd.)
Substation
Switchgear and relays will not operate causing
extensive damage to transformers and power lines
PLCC
Extremely difficult to resynchronise the unit with the
grid
Major setback in the process of reviving the grid in the
event of a regional grid failure
If the battery fails while the unit is in operation, it may
become essential to shutdown
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4 February 2010
The Single Most Important Feature Of Storage Batteries For
Power Sector and Other Critical Standby Application Is
Reliability
Reliable standby power source
Deliver power as and when called for
Full capacity at any point of time in service lifePredictability
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EITHER
SUDDEN DISRUPTION OF MAINS POWER TAKES PLACE
OR
CONVENIENT AVAILABILITY OF MAINS POWER IS NOT THERE
THIS CLEARLY DEFINES TWO REGIMES OF APPLICATION
STANDBY APPLICATION
CYCLIC APPLICATION
UPS, INVERTERS, TELEPHONE
EXCHANGES, POWER STATIONS,
SWITCHING
CELL PHONES, TOYS, FORK
LIFTS, ELECTRIC VEHICLES,
SOLAR PHOTOVOLTAICS
STORAGE BATTERY
WHEN ?
4 February 2010
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SELECTION HEURISTICS
SELECTION OF RIGHT
TECHNOLOGY
KNOWLEDGE OFATTRIBUTES OF
COMPETING
TECHNOLOGIES
KNOWLEDGE OF
ATTRIBUTES OF
DESIGN OPTIONS
KNOWLEDGE OF
APPLICATION
REQUIREMENTS
CALCULATION OFCORRECT CAPACITY
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LEAD ACID
NICKEL CADMIUM
General Battery Technologies
Most Popular Electrochemical Couples used worldwide in
Industrial Application
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BASIC ELECTROCHEMISTRY
PbO2 + Pb + 2H2SO4 PbSO4 + PbSO4 + 2H2O
CHARGED DISCHARGED
ELECTROLYTE TAKES ACTIVE PART IN REACTIONSPECIFIC GRAVITY
CHANGES WITH STATE OF CHARGEEASY MONITORING AND INDICATION
OF STATE OF CHARGE (SOC)
2NiOOH + 2H2O + Cd 2Ni(OH)2 + Cd(OH)2NEG. NEG.POS POS
DISCHARGEDCHARGED
ELECTROLYTE DOES NOT TAKE ACTIVE PART IN REACTIONSPECIFIC
GRAVITY DOES NOT CHANGE WITH STATE OF CHARGENO DIRECT &
EASY METHOD OF MEASURING STATE OF CHARGE
NEG. NEG.POS POS
LEAD ACID
NICKEL CADMIUM
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More than 90% of applications world-wide use
Lead-acid
Reasons:
LOW COST
APPLICATION VERSATILITY
ABUNDANT RAW MATERIAL
WELL DEVELOPED SERVICING RECYCLING
INFRASTRUCTURE
Advantage Lead Acid
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Technology Wise Categorisation
Industrial Lead Acid Battery
FLOODED VRLA
FLAT TUBULAR PLANTE
The Lead-Acid Technology
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LEAD ACID BATTERY AN OVERVIEW
ACTIVEMATERIAL
TAKES ACTIVE PART IN
REACTION TO STORE &SUPPLY ENERGY
SUPPORT
STRUCTURE
ENABLES ELECTRONIC
CONDUCTION1
2
PROVIDES MECHANICAL
SUPPORT TO ACTIVE
MATERIAL
ACTIVE MATERIAL
SUPPORT STRUCTURE
PLATES ARE
CONSTITUTEDOF
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FLAT PLATE DESIGN
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FLAT PLATE MORPHOLOGY
A CHEMICAL BONDING HOLDS THE ACTIVE
MATERIAL IN PLACE THROUGHOUT THE
SERVICE LIFE
WIRE-MESH LIKE SUPPORT
STRUCTUREGRID CAST OF LEADALLOY, ANTIMONY OR CALCIUM
ACTIVE MATERIAL
PASTED ON GRID -EXTERNALLY
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FLAT POSITIVE PLATE
MOST SUITABLE FOR HIGH CURRENT, SHORT DURATION
APPLICATION viz. SLI, SHALLOW DUTY INVERTER ETC.
ADVANTAGES
MINIMUM LEAD MOST ECONOMIC & HIGHESTENERGY DENSITY
EXCELLENT HIGH RATE
DISCHARGE PERFORMANCE
AND CHARGE ACCEPTANCE
LARGE ACTIVE
SURFACE AREA
LIMITATIONS
ACTIVE MATERIAL
SHEDDINGLIMITED CYCLING
CAPABILITY
EASY ACCESS OF
ACID TO LEAD GRIDEASY CORROSION LOW
LIFE EXPECTANCY
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TUBULAR PLATE DESIGN
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TUBULAR POSITIVE PLATE MORPHOLOGY
SPINE
PLASTIC BOTTOM BARGAUNTLET
ACTIVEMATERIAL
GAUNTLET + BOTTOM BAR + LEAD TOP BAR
RETAINS THE ACTIVE MATERIAL
LEAD TOP BAR
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EXTENDED SERVICE LIFE. IT IS DESIGNED FOR DEEP CYCLING
LOOSE PACKING OFACTIVE MATERIAL
POSSIBLE
ADVANTAGES
NO ACTIVE MATERIALSHEDDING
BEST SUITED FORCYCLING1500 CYCLES
@ 80% DOD
SPINE DEEPLY
EMBEDDED IN ACTIVE
MATERIALLOW SPINECORROSION
EXTREME TEMPERATURE
OPERATION
RESISTANT TO OVER-
CHARGE
RECOVERY FROM DEEP
DISCHARGE
PSOC OPERATION
TUBULAR POSITIVE PLATE WHY ?
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MODEST HIGH RATE DISCHARGEPERFORMANCE.
REQUIRES PERIODIC EQUALIZING AND/OR
BOOST CHARGING
REQUIRES PERIODIC TOPPING UP
ANTIMONY POISONING LEADS TO SLOWLYDECLINING VOLTAGE PROFILE AND
INCREASING WATER LOSS AS THE BATTERY
AGES.
TUBULAR POSITIVE PLATE WHY NOT ?
LIMITATIONS
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TUBULAR
Are all the Tubulars
Same ??
The answer is an emphatic NO !!!
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Exide OPzS
The Next Generation Tubular Battery
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HIGH PRESSURE SPINE CASTING IN HADI MACHINES
GRAVITY CAST (1 Bar) CAST IN LOW PRESSURE (10 Bar) CAST IN HADI (100 Bar)
Exide has introduced a unique hybrid concept in this country. Lowantimonial positive spine alloy with lead-calcium negative. This togetherwith the benefit of Hadi casting leads to:
Extremely Corrosion Resistant Positive Alloy
Drastically reduced water loss
Exide OPzS comes with Heavy Duty DIN standard Spines
Exide OPzS
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Comparative Water Loss study data:
Positive
Spine Alloy
Negative
Grid Alloy
Rate of water loss on float # per
Ah/Cell/21 days at 50oC, 2.4 V/cell
Till late 80 9% Sb 5% Sb 1.10 gms.
Post 90 5% Sb 2.5% Sb 0.55 gms
Exide OPzS 2.5% Sb 0.1% Ca
0.3% Sn
0.18 gms
# Test Specification as per RDSO low maintenance battery requirements
In the absolute worst case too, cells do not require topping up in 1 year!!
Exide OPzS
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The Exide OPzS range of Tubular CellsNow come in transparent, tough Styrene-Acrylonitrile (SAN) boxes clear as glass.
Exide OPzS
Easy to monitor State-of-Health !!
Additional Features
Ceramic Dome Filter
Plastic Encapsulated
Strap for corrosionresistance
Low foot print
Insulated Connectors
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PLANTE PLATE DESIGN
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EXIDE PLANTE
4 February 2010
PLANTE
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CAST OF 99.99%
PURE LEAD
LAMELLAR GRIDSTRUCTURE
ENHANCED
ACTIVE SURFACE
AREA
INTEGRAL GRID
ACTIVE MATERIAL
PLANTE MORPHOLOGY
4 February 2010
PLANTE HANGING PLATE DESIGN
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POSITIVE PLATE HANGING FROM
CONTAINER SHOULDER
GAP BETWEEN POSITIVE PLATE
BOTTOM & MUD RIB FOR CREEP
GROWTH ALLOWANCE
POSITIVE PLATE
HANGING FROM
CONTAINER SHOULDER
TO PROVIDE SPACE FOR
CREEP GROWTH
INEVITABLE TO PURE
LEAD POSITIVE
PLANTE HANGING PLATE DESIGN
4 February 2010
I t l G id A ti M t i l
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1. In case of loss of active material due to shedding, nextlayer of pure lead is converted to lead-dioxide therebyensuring no loss of capacity feature of continuousregeneration of active material.
2. Across its life time Plante cells therefore perform at fullcapacity there is no aging unlike all other lead-acidproducts.
3. No aging factor required for capacity calculation
Integral Grid-Active Material
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FLOATCURR
ENT
SERVICE LIFE
10 A
20 Yrs.
Plante
10yrs
SbCdVRLA
Low Sb Tubular
NormalTubular
FLOAT CURRENT VS SERVICE LIFE
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CONTINUOUS REGENERATION OF ACTIVE MATERIAL
PLANTE NO LOSS IN CAPACITY
TOTAL LEAD-DI-OXIDE CONTENT FAIRLY
CONSTANT THROUGHOUT THE LIFE
SPAN INDICATING A CONSTANT
CAPACITY OUTPUT
CAPACITY DEGRADATION OVER LIFE AGEING FACTOR
TUBULAR : 20% 1.25
VRLA : 20% 1.25
Ni-Cd : 20% 1.25
PLANTE : ZERO 1.00
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HIGH SURFACE AREA
HIGH CHARGING RATES POSSIBLE.
CHARGING AT 0.25 C10 AMPS UPTO
2.4 VOLTS PER CELL WITHOUTPROBLEM
NO ANTIMONY POISONING
HIGH FLOAT POTENTIAL POSSIBLE.
PLANTE FAST RECHARGE
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LIFE EXPECTANCY OF 15 TO 20 YEARS PLUS.
PLANTE LONG LIFE
VERY THICK POSITIVE ENOUGH CUSHION AGAINST
CORROSSION
LOW SUSCEPTIBILITY TO OVERCHARGE DUE TO
VERY LOW EQUILIBRIUM FLOAT CURRENT OFTHE ORDER OF 1 mA/AH UNDER NORMAL FLOAT
CONDITION
LOW FLOAT CURRENT AND HIGH PURITY OF LEADLOWERS THE CORROSSION RATE
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RELIABILITY - REITERATED
PLANTE EASY MONITORING
TRANSPARENT SAN (STYRENE ACRYLONITRILE)
CONTAINER EASY VISUAL MONITORING OF CELL INSIDE
ANY ODD BEHAVIOUR CAN BE MONITORED ANDCORRECTED MUCH BEFORE IT SHOWS UP AS A
FAILURE MODE
EASY CLEANING OF CELLS FROM UNAVODABLE
SLUDGE DEPOSITION TO AVOID SHORT CIRCUITAND RELATED TROUBLES
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VRLA DESIGN
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SEALED ! CAN BE KEPTIN ANY ORIENTATION.
NO TOPPING-UP REQUIRED
EVER MAINTENANCE-FREE.
A ZERO EMISSION PRODUCT.
BATTERY COMES CHARGED.
COMPACT.
WHAT IS VRLA ?
4 February 2010
Advantage VRLA
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1. No topping up ever2. No emission of fumes3. Supplied factory charged4. Excellent high rate discharge performance5. Excellent charge acceptance6. Excellent deep cycle life7. Low Self-discharge8. Designed to suit float and moderate cyclic duty
9. Compact low foot print10.Long Life
Advantage VRLA
4 February 2010
The Oxygen Recombination Cycle
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+ -
H + H +
At +ve Electrode At -ve Electrode
H2O=1/2O2 + 2H
+ +2e- 2Pb + O2= 2PbO (Exothermic Reaction)PbO + H2SO4 = PbSO4 + H2O (Exothermic Reaction)
PbSO4 + 2e- + 2H+ = Pb + H2SO4 (Electrochemical Reaction)
Charger
MECHANISM DURING CHARGING
FLOODED SYSTEM
O2 H2
e-
i
+ -
H + H +
Charger
e-
i
V R L A
SYSTEM
O2
O2
2Pb + O2= 2PbO
PbO + H2SO4= PbSO4 + H2O
PbSO4 + 2e-
+ 2H+
= Pb + H2SO4
ABSORPTIVE SEPERATOR - ELECTROLYTEELECTROLYTE - H2SO4
The Oxygen Recombination Cycle
RECOMBINATION MECHANISM OF VRLA CELLS WITH MICRO GLASS
SEPERATORS IN COMPARISON WITH FLOODED CELLS
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Venting Arrangement Of A VRLA Battery
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VRLA Limitations
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1. No means of state-of-charge assessment
2. Vulnerable to prolonged operation at high temperature
3. Sensitive to both under and over charge
4. Recovery from over discharged condition is difficult
5. Can have a catastrophic failure in case of chargermalfunction and/or abnormally high temperatureoperation a failure mode known as thermal runaway
VRLA Limitations
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SIZING FACTORS PARAMETERS
PRIMARY
LOAD CURRENT
LOAD DURATION
NOMINAL SYSTEM VOLTAGE
MINIMUM SYSTEM VOLTAGE
MINIMUM OPERATING TEMPERATURE
DESIGN MARGIN
AGEING FACTOR
SECONDARY
FACTORS SPECIFIC TO APPLICATION
4 February 2010
Selection Parameters
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DEPTH OF DISCHARGE
FREQUENCY OF DISCHARGE
APPLICATION CRITICALITY
CHARGING CONSTRAINT
MAINTENANCE CONSTRAINT
OPERATING CLIMATIC CONDITIONS
SELECTION OF THE RIGHT TYPE OF TECHNOLOGY AND
DESIGN PRECEDES THE SIZING EXERCISE
PARAMETERS
TO BE
CONSIDERED
FOR SELECTION
4 February 2010
Selection Summary
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APPLICATION
ATTRIBUTE
HIGH MODERATE LOW
DEPTH OF
DISCHARGETUBULAR
TUBULAR /
VRLA
VRLA /
PLANTE
FREQUENCY OF
DISCHARGETUBULAR
TUBULAR /
PLANTE
PLANTE /
VRLA
CRITICALITY OFAPPLICATION
PLANTE PLANTE /TUBULAR
TUBULAR /VRLA
CHARGER
CONSTRAINT ON
VOLTAGE
TUBULAR - -
MAINTENACECONSTRAINT
VRLA PLANTE /TUBULAR
PLANTE /TUBULAR
OPERATING TEMP.TUBULAR /
PLANTEPLANTE / VRLA VRLA
Selection Summary
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BATTERY SIZING
4 February 2010
Sizing Parameters
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g
APPLICATION
PARAMETERS
DUTY CYCLELOAD CURRENT
AND DURATION PATTERN
OPERATING DC BUS VOLTAGE
WINDOWMAXIMUM & MINIMUM
DC BUS VOLTAGES
MINIMUM AMBIENT TEMPERATURE
DESIGN MARGIN
BATTERY
PARAMETERS
CHARGING VOLTAGE REQUIREMENT
DISCHARGE CHARACTERISTICS
FACTOR FOR AGING PHENOMENON
FACTOR FOR STATE-OF-CHARGE IF
REQUIRED
4 February 2010
STEP1 : CALCULATION OF NUMBER OF CELLS
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CHARGING
VOLTAGE PER CELL
VC
MAX. DC BUS
VOLTAGE VMAX
NOMINAL VOLTAGE
PER CELL, V
NOMINAL DC BUS
VOLTAGE VDC
NUMBER OF CELLSVMAX / VC
VDC / V
MIN. DC BUS
VOLTAGE VMIN.
END OFDISCHARGE
VOLTAGE
(ECV)
4 February 2010
STEP2 : CALCULATION OF BASIC CAPACITY
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CAPACITY FACTOR
F
BASIC RATED CAPACITY OF THE CELL
C = I X F
LOAD CURRENT, I
END OF DISCHARGE
VOLTAGE
TYPE OF CELL
SELECTED
BACK-UP DURATION
REQUIRED
4 February 2010
STEP3 : CALCULATION OF FINAL CAPACITY
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BASIC RATED CAPACITY OF THE CELL
C = I X F
FINAL CALCULATED CAPACITY
CF = C X A X D X KTX Z
FACTOR FOR AGING,
A
FACTOR FOR
TEMPERATURE
CORRECTION, KT
DESIGN MARGIN, D
STATE-OF-CHARGE /
FLOAT CHARGE
CORRECTION
FACTOR, Z *
* REQUIRED ONLY FOR Ni-Cd BATTERY
4 February 2010
Multi-step Load
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p
P = PERIOD
S = SECTION
Sn = Pn
CS = (A PA P-1) X FTP = 1
P = S
C = MAX. CSS = 1
S = N
4 February 2010
SOFTWARE ALGORITHM
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BATTERY SIZINGTOOLKIT
SELECTED
MODEL
NO. OF
CELL
USERS
CONFIRMATION
ENVIRONMENT
PARAMETERS
SYSTEM
PARAMETERS
LOAD
PARAMETERS
BATTERY TYPE
SELECTED
SIZING CALCULATION
GUARANTEED TECH PARTUCULARS
STANDARD LAYOUT
PRODUCT CATALOGUE
O & M MANUAL
4 February 2010
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THANK YOU
4 February 2010