The document discusses battery monitoring and provides information on why daily monitoring of batteries is important. It notes that battery failures can occur within just 2 days and that quarterly or less frequent monitoring leaves critical systems exposed to failure for prolonged periods. The document advocates for Cellwatch, a battery monitoring system that monitors batteries daily through measuring voltage, current, temperature and importantly, ohmic values to detect failures early and prevent outages.
Monitoring of Lead Acid Batteries - an Eltek White PaperEltek
Eltek's Gunnar Hedlund demonstrates different methods of predicting premature capabity loss in your battery park.
No foolproof indicators/tools for knowing and predicting the health and life of a lead acid battery have been evolved or devised. The only way to truly determine the health of a standby lead-acid battery is to perform a 100 % capacity test, according to the battery manufacturers discharge table.
Such a capacity test means that the battery needs to be disconnected from the load and another back-up battery connected when the capacity test is performed. However, comprehensive controllers and instruments are now able to find failing cells without this test and while the battery system is online.
A large number of techniques have been explored and tried out in the field. No single method or test instrument is capable of foolproof prediction about the residual capacity without performing a 100% capacity test. On the other hand, by combining some of them the state of health and expected residual life of the battery can be predicted more precisely and reliably. This is especially true in the finding of failing cells in a standby lead-acid battery.
Dave Marlow, Certified Biomedical Equipment Technician at the University of Michigan, presents Rechargeable Battery Management Guidelines for optimizing the life of NiMH, NiCD, Lithium Ion, and Lead Acid batteries for the Association for the Advancement of Medical Instrumentation.
The CTEK Smarter Charger effectively manages your battery resulting in reduced ‘warranty ‘ handling costs and reduced end user downtime. It also maximizes equipment productivity and increases customer satisfaction Having a longer, more effective battery life creates a happy customer and a better environment.
The right pressure transmitter can enhance production. The key to maximizing the return on oil and gas development projects rests with the maintenance and safety of your—sometimes—aging equipment.
UTC Telecom & Technology 2015 - Battery Backup WorkshopDakx Turcotte
This is the battery backup workshop slides that were presented as part of the UTC Telecom & Technology 2015 Conference that occurred in Atlanta, GA on the morning of May 5, 2015. Subjects covered: what's a battery, what's the role of a technician with regards to battery backup & what's the role of an engineer with regards to battery backup.
In a variety of industrial projects, different practices of equipment maintenance are followed. Latest
maintenance technologies are used to improve the efficiency of equipment as well as to reduce the chances of
fault occurrence. The different types of maintenance are listed as: Preventing schedule breakdown and
Predictive & Conditions based maintenance. All types of electrical motors, circuit breakers, isolators, fuses and
various other equipment’s need periodic maintenance. In an industry, various maintenance functions have to be
integrated together along with other operations so as to have effective and desired results.These projects aim in
utilizing latest technologies of maintenance and with a range of practices which can improve reliability of
system, extension in life of equipment, lesser asset replacement and improve employer’s safety.
Liquid Insulation Dissipation factor and Dielectric Factor Measurement UnitNadiiaHubar
The unit is designed for determining dielectric loss tangent and permittivity of transformer oils and other dielectric fluids according to the IEC 60247 and the corresponding national standards GOST 6581-75.
Monitoring of Lead Acid Batteries - an Eltek White PaperEltek
Eltek's Gunnar Hedlund demonstrates different methods of predicting premature capabity loss in your battery park.
No foolproof indicators/tools for knowing and predicting the health and life of a lead acid battery have been evolved or devised. The only way to truly determine the health of a standby lead-acid battery is to perform a 100 % capacity test, according to the battery manufacturers discharge table.
Such a capacity test means that the battery needs to be disconnected from the load and another back-up battery connected when the capacity test is performed. However, comprehensive controllers and instruments are now able to find failing cells without this test and while the battery system is online.
A large number of techniques have been explored and tried out in the field. No single method or test instrument is capable of foolproof prediction about the residual capacity without performing a 100% capacity test. On the other hand, by combining some of them the state of health and expected residual life of the battery can be predicted more precisely and reliably. This is especially true in the finding of failing cells in a standby lead-acid battery.
Dave Marlow, Certified Biomedical Equipment Technician at the University of Michigan, presents Rechargeable Battery Management Guidelines for optimizing the life of NiMH, NiCD, Lithium Ion, and Lead Acid batteries for the Association for the Advancement of Medical Instrumentation.
The CTEK Smarter Charger effectively manages your battery resulting in reduced ‘warranty ‘ handling costs and reduced end user downtime. It also maximizes equipment productivity and increases customer satisfaction Having a longer, more effective battery life creates a happy customer and a better environment.
The right pressure transmitter can enhance production. The key to maximizing the return on oil and gas development projects rests with the maintenance and safety of your—sometimes—aging equipment.
UTC Telecom & Technology 2015 - Battery Backup WorkshopDakx Turcotte
This is the battery backup workshop slides that were presented as part of the UTC Telecom & Technology 2015 Conference that occurred in Atlanta, GA on the morning of May 5, 2015. Subjects covered: what's a battery, what's the role of a technician with regards to battery backup & what's the role of an engineer with regards to battery backup.
In a variety of industrial projects, different practices of equipment maintenance are followed. Latest
maintenance technologies are used to improve the efficiency of equipment as well as to reduce the chances of
fault occurrence. The different types of maintenance are listed as: Preventing schedule breakdown and
Predictive & Conditions based maintenance. All types of electrical motors, circuit breakers, isolators, fuses and
various other equipment’s need periodic maintenance. In an industry, various maintenance functions have to be
integrated together along with other operations so as to have effective and desired results.These projects aim in
utilizing latest technologies of maintenance and with a range of practices which can improve reliability of
system, extension in life of equipment, lesser asset replacement and improve employer’s safety.
Liquid Insulation Dissipation factor and Dielectric Factor Measurement UnitNadiiaHubar
The unit is designed for determining dielectric loss tangent and permittivity of transformer oils and other dielectric fluids according to the IEC 60247 and the corresponding national standards GOST 6581-75.
2. 08/23/10 What is battery monitoring Is a method to monitor rechargeable batteries By wikipedia Battery Monitoring is, The tools to verify a batteries ability to supply design current under rated load Battery facts >>
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4. 08/23/10 Normal Conditions: 40 x 12 volt jars = 480V The vulnerability of a string >> Single Battery Failure: 40 x 12 volt jars = 0V 40 Jar Cabinet Contains 240 Individual Cells
10. 08/23/10 Cellwatch Monitors… >> Daily Cell or Jar/Block Ohmic Value (low energy) Daily Cell or Jar/Block Voltage Discharge Current String Voltage Discharge Time String Currents Pilot Temperature Ambient Temperature
11. 08/23/10 Alber Monitors… >> Monthly Cell or Jar/Block Ohmic Value (low energy) Daily Cell or Jar/Block Voltage Discharge Current String Voltage Discharge Time String Currents Pilot Temperature Ambient Temperature
12. 08/23/10 Btech Monitors… >> Bi-Monthly Cell or Jar/Block Ohmic Value (low energy) Daily Cell or Jar/Block Voltage Discharge Current String Voltage Discharge Time String Currents Pilot Temperature Ambient Temperature
13. 08/23/10 PM Monitors… >> Quarterly Cell or Jar/Block Ohmic Value w/Cellcorder Quarterly Cell or Jar/Block Voltage NA……………..…Discharge Current UPS ………………String Voltage UPS ………………Discharge Time NA ………………..String Currents NA …………………Pilot Temperature NA …………………Ambient Temperature
14. 08/23/10 >> Let us say your monitor checked your batteries on the 1st of September The jar has fully failed on the 5 th . 4 days later Some monitors only recommend testing every 14 days in this case leaving the customer exposed with a failed battery for 9 days Some monitors even recommend testing only every 28 days in this case leaving the customer exposed to battery failure for a whole 23 days! Quarterly maintenance
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16. 08/23/10 Why not Battery Monitoring? Why you don’t need Cellwatch >>
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18. 08/23/10 >> Hourly costs of unplanned downtime Up to $50K 46% $50k to $250K 28% $251k to $1M 18% Over $1M 8%
19. 08/23/10 Still at risk of battery failure because you are not checking them daily. Up to 5% of batteries fail during the warranty period, 2-3 years Throwing away a high percentage of good batteries after 4 years Throwing away dollars, odds are better, but you are still betting Increased downtime, running on Generator, switching loads, increased opportunity for system failure Environmental issues caused (disposal) Expense of disposal Who’s watching it when the installers go home? “ I change my batteries every four years” >> Why you don’t need Cellwatch
20. 08/23/10 Servicing is better than no servicing but: Still at risk of battery failure because you are not checking them daily. Four times a year is not enough in today’s critical uptime environment Handheld testing is not as repeatable as Cellwatch Discharge tests, adverse effect on weak cells What happens when the service engineers go home? No real status on battery condition for 361 days out of 365. “ I have a battery service contract” >> Why you don’t need Cellwatch
21. 08/23/10 Still at risk of battery failure because you are not checking them daily. Does not give battery security unless it is used every day Best case…no real battery status for 25% of the time (assuming a test every month). Worst case…no real battery status for 92% of the time (assuming quarterly testing) Not as repeatable as Cellwatch Who is trending the data? Much more labor intensive Much more risk prone, safety issues (for the tester, the company and the battery) Long downtime is essential each time it is used “ I have a handheld tester” >> Why you don’t need Cellwatch
22. 08/23/10 Still at risk of battery failure because they won’t recommend daily testing of ohmic values. Cellwatch measures ohmic value daily and was specifically designed to do so Cellwatch pioneered ohmic measurements in 1996 and still leads the way Competitors “hit” their batteries with a much larger test load so have to recommend doing ohmic testing less often Some competitors do not measure ohmic value at all Cellwatch is the easiest, simplest and hence the quickest to install Large conduit and cable-tray considerations with these older systems. Competitors system constraints make a cluttered installation “ I always use another make of monitor” >> Why you don’t need Cellwatch
23. 08/23/10 Courtesy - C&D Technology Inc >> C & D batterie’s recommendations In the late 1990s, Johnson Controls, (now C&D Batteries), produced a very comprehensive set of literature on battery behavior. One of these is called: “Impedance and Conductance Testing” (Now referred to as Ohmic testing)
24. 08/23/10 Courtesy - C&D Technology Inc >> C & D batterie’s recommendations It also said that: “… actual values may vary +/-20% from value shown… The significance of values measured lies not so much in the specific value but how the value changes from its original value over a period of time.”
25. 08/23/10 This graph shows that with normal ageing these batteries have increased their ohmic value by 14% over 3 years (average) >>
26. 08/23/10 If we take 2.4mOhms as the start point, Cell 1 reaches an increase of 25% on May 30th Because Cellwatch measures daily Cell 1 is changed out immediately after the first alarm safeguarding the battery and the load!! >> Assuming the same delivery time to get a replacement cell, other monitoring systems could have left the customer exposed for much longer periods. Quarterly maintenance only could mean up to 119 days exposure!
27. 08/23/10 Manual testing vs. Cellwatch Only IEEE Cellwatch does not meet is the Visual Checks IEEE recommended maintenance (IEEE 1188) >> IEEE 1188 Manual System Cellwatch Monthly System Float Voltage, Charger current, Temperature and ventilation and visual checks Constantly (Not ventilation although temp can indicate failed AC) Not visual Quarterly Monthly checks plus – Cell / unit ohmic values, negative terminal temperature, interconnect resistance. Voltage every hour, ohmic once a day Semi-annual All monthly and quarterly plus – Voltage of each cell / unit Voltage every hour, ohmic once a day Yearly All the above plus cell to cell and interconnect resistance. Performance Test Voltage every hour, ohmic once a day. Any discharge gives a graph of voltage performance under load
31. 08/23/10 Cellwatch systems are supporting critical loads in over 30 countries around the World There are no customers, operating Cellwatch who have had a “ dropped” load due to battery failure. The reason? Cellwatch is designed to monitor batteries for ohmic value DAILY Cellwatch allows full visibility of the TOTAL battery install (including the generator) High level of reliability is maintained by changing suspect cells well before a failure occurs Many Cellwatch systems pick up battery faults on install Allows 24/7 monitoring Gives REAL usable data of each cell or jar/bloc in the battery system Cellwatch around the World >>
32. 08/23/10 Daily monitoring of ohmic values Advanced optical technology CE & UL certified Continuous monitoring 24/7 Scalable system Fiber optic data highway Easy to install, u ser friendly software Measures: v oltage, ohmic value, current and temperature Actual on-battery indication of failed cell location Full d ischarge recording Remote monitoring facilities Web browsing, Email alert, SMS Cellwatch features >> y=m 1 x 1 + m 2 x 2 + b
33. 08/23/10 Eliminates costly downtime and disruption due to battery failure Daily surveillance of ohmic values, 24 x 7 watchdog Uses trending to highlight weakening cells prior to failure thereby predicting battery failure Optimizes battery assets by only replacing weak cells Full cell/bloc history allows validation of battery warranty claims Proactive versus reactive battery asset management The benefits of Cellwatch >>
34. 08/23/10 If its not everyday its not battery monitoring End presentation PTI Cellwatch >>
Editor's Notes
The IEEE 1188 specification details the recommended practices in maintaining VRLA lead acid batteries. It can quickly be seen that with the exception of ventilation and visual checks, the Cellwatch system performs all of the recommended tests. The difference is in the frequency of the tests. With Cellwatch an automatic cycle has been established that results in complete system testing every 12 hours. The storage of test results and notification through alarms is incomparable with manual test procedures.
Cellwatch equipment conducts full voltage and Internal Resistance testing of every measurement point (cell). Testing frequency can be adjusted but allows a maximum of full voltage and resistance testing every six hours – every day – every week etc. In a discharge state the system recognizes that valuable battery data is being generated and that as many voltage measurements as possible need to be taken. The system rapidly cycles through every cell taking voltage measurements and the repeats the process until the discharge cycle is complete. The flexibility provided by the modular design results in an unlimited range of solutions and every conceivable configuration can be catered for. The software has extensive graphing and graphical capabilities which results in an intuitive understanding of the data. The Cellwatch system is UL approved and CE marked. The modular design, robust construction and high quality engineering results in a plug and play installation. Provision of an external telephone line on site results in the ability for dial in to the site for consultation.