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]

Let’s Take a Quick Look At The Evolution of Grid Types

The Types of Grids Used with Lead Acid Batteries

Pure Lead

Manchex

L d A tiLead Antimony

Lead CalciumLead Calcium

Lead SeleniumLead Selenium

Let’s Examine the Advantages/DisadvantagesAdvantages/Disadvantages

of each Grid Type

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]

.

BAE FLAT PLATE GRID DESIGNBAE FLAT PLATE GRID DESIGN

from Dr. Rusch paper [see catalog]

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

I S In Summary . . .

ALL CELLS ARE NOT CREATED EQUAL!

All Cells are Not Created EqualAll Cells are Not Created Equal

Thank You Very Much for your Time and AttentionTime and Attention

Chris Searles

BAE Batteries USA