Industrial Battery

Comparison
 Safety Precautions
 MSDS Sheets identify chemical hazards
 Use double insulated tools
 No smoking or open flames
 Avoid arcing near the battery
 Wear personal protective equipment
 Avoid wearing metal objects
 Ensure battery area ventilation is operable
 Neutralize static buildup

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 SAFT, now proud part of the TOTAL Group*

SAFT DEVELOPS AND MANUFACTURES ADVANCED-TECHNOLOGY BATTERY SOLUTIONS

FOR MULTIPLE APPLICATIONS ON A GLOBAL SCALE

 Diversified base of industries

35% 32%
 Broad portfolio of technologies North
Europe
(Ni-based, Primary Lithium and Lithium-ion) America
33%
Asia, MEA,
 Leadership positions on 75-80% of Latam
revenue base (Industrial Standby, Metering,
Aviation, Rail, Defense, Satellites)

* SAFT is part of TOTAL new division, “Gas, Renewables & Power”, since September 1st, 2016

100 $921M* 9.7% +4,100 +3,000

years of history revenue FY 2017 invested in R&D people customers

3 *Using an exchange rate of 1.24 Saft proprietary information – Confidential

Leading Oil & Gas companies rely on Saft

International & National Oil and Gas Companies

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 1 Battery Basics

2 Battery History

3 Chemistries and Construction

4 Battery Comparison

5 Choosing the Right Technology

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 BATTERY BASICS

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Battery Composition

A battery is an electrochemical energy storage device.

Energy Storage Active Material Electrolyte

= +
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Stationary Battery Cell Components

Substrate
Bones of the battery.
Physical structure inside the battery
that houses the active materials.
(May or may not be made of the
same material as the active
material)

Active Material
The muscles of the battery.
The material that does all the work
storing and releasing energy.

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Stationary Battery Cell Components

Electrolyte
The life blood of the battery.
Carries energy between the plates.
(May help with energy storage in
some battery types)

Case (Jar)
Skin of the battery.
Keeps all the important bits inside!!

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 Stationary Battery Assembly

Battery System Configurations

Capacity Increase

+ _

Voltage Increase

Cells in series increase voltage

Cells in parallel increase capacity
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 Battery Failure modes

Two Basic Failure Modes

Battery Type A
Fails open circuit
Hi!

Open: No current path

Battery Type B
Fails short circuit

Short: Healthy cells provide power

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 Battery Terms

1 hour

Ah – Ampere-hours
• Battery’s rating of capacity 1 amp = 1 amp/hour
Rated capacity of a battery
• Continuous amps available for a set time period, to a certain end of discharge
voltage, at a stated temperature
• Ni-Cd Example: 100Ah = 20A for 5 Hours down to 1.00 Volts/cell at 77°F
5 hours

100 AH Ni-Cd Battery = 20 amps

Power = Instantaneous (V x I)
• Example: Switchgear Tripping current, instantaneous power requirement.
Energy = Power x Time
• Example: Continuous current loads for many hours.

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 BATTERY HISTORY

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 Battery Basics - History

The Early Days of Batteries

Gaston Plante Waldemar Jungner
• French Physicist • Swedish Chemist
• Invented the first rechargeable • Invented the first rechargeable
(secondary) lead-acid battery nickel-cadmium battery in 1899
in 1859

1802 1836 1859 1868 1888 1899 1901 1932 1947 1960 1970 1990

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 SAFT History

• Founded in 1918 by Victor Herald

• Originally Société des Accumulateurs Fixes et de Traction (S.A.F.T.)
• Roughly translates to "Stationary and Traction Battery Company"

1802 1836 1859 1868 1888 1899 1901 1932 1947 1960 1970 1990

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 Battery Basics - History

Traditional Battery Improvements…

• 1970’s: the development of valve regulated

lead-acid batteries

• 1980’s: Saft introduces “ultra low”

maintenance nickel-cadmium batteries

• 2010: Saft introduces maintenance-free*

nickel-cadmium batteries
○ The term maintenance-free means the
battery does not require water during it’s
entire service life (20+ years under Saft’s
recommended conditions)

1836 1859 1868 1888 1899 1901 1932 1947 1960 1970 1990 2010

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 Battery Basics - History

The future of batteries – Lithium-ion

• 1976: Exxon researcher – Whittingham

described lithium-ion concept in Science
publication entitled “Electrical Energy Storage
and Intercalation Chemistry”

• 1991: Sony introduced the first Li-ion cell

(18650 format)

• 1992: Saft introduced its commercially

available Li-ion cell

1836 1859 1868 1888 1899 1901 1932 1947 1960 1970 1990 2010

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 CHEMISTRIES &
CONSTRUCTION

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 Lead-Acid Basics

• Plates –
○ Substrate: Pure lead or lead alloy grid
○ Positive Active Material: Lead oxide
○ Negative Active Material: Sponge lead

• Electrolyte - Sulfuric acid (H2SO4) 1.205 - 1.275 Specific Gravity

and participates in the electrochemical storage reaction

• PH = ~2

• Nominal volts per cell ~2.0

• Inter-cell connection links - usually lead plated copper

• Different Grid Alloys – Selenium, Calcium, Antimony

• Failure mode: OPEN CIRCUIT

• Total Reaction
- +

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 Flooded Lead-Acid Pasted Plate

Basic Specification

• Jars - Styrene AcryloNitrile (SAN) or PolyCarbonate (PC),

• Flame Retardant - ABS Lid-opaque, PC Jar-clear

• Construction: Plante, Manchester, Faure (Pasted Plate), Tubular

• Design Life - 20 years

• Service life - 12 – 15 yrs, depending on environment, design, application

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 Lead acid electrodes design

Pasted plates Tubular plates Plante lead plate

Negative plate

Lead grid

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 Valve Regulated Lead-Acid Batteries

VRLA or Recombination Technology

• Immobilized electrolyte
○ Absorbed (AGM)
– Fiberglass mat saturated with acid
○ Gel Cells
– Silicon gel saturated with sulfuric acid
– Gas path from positive to negative

• Positive internal pressure

• Recombination process is highly efficient due to

low electrolyte content
○ Charging energy is converted to heat
○ Thermal management is critical

• Grid corrosion results in hydrogen evolution

• Typically have FR (Flame Retardant) jars

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 VRLA (continued)

Advantages
• No water additions
• High energy density
• Low initial cost
Disadvantages
• Multiple failure modes
○ Dry out
○ Thermal runaway
○ Negative strap corrosion
○ Sudden death… OPEN CIRCUIT
• Highly susceptible to ripple current
• Shorter life than vented cells
• Design Life:1-11 years
• Service Life: typically 3 – 7 years

Typical Applications
• Telecommunications, UPS, Emergency Lighting

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25
High Temperature Sudden Death Thermal Runaway

Corrosion
Ripple Current

LCC
High
VRLA Battery Failure Modes: Summary

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Sulfation Dry Out Storage

 Nickel-Cadmium Basics

• Plates –
○ Substrate: Nickel-plated Steel
○ Positive Active Material: Nickel hydroxide
○ Negative Active Material: Cadmium
• Electrolyte = Potassium Hydroxide (KOH)
• PH = ~11
• Electrolyte is alkaline and does not corrode the plates or
participate in the electrochemical reaction. It is actually a
preservative of the plates.
• Nominal volts per cell ~1.2
• Failure Mode: SHORT CIRCUIT
• Different plate types: Pocket, Fiber, Sintered, Plastic Bonded
(PBE)
• Total Reaction -

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 Nickel Cadmium Features

Advantages
• Most rugged battery type. All steel plate construction
• Resistant to: Electrical abuse, overcharging / over-discharging
• Physical abuse, extreme temperatures, shock & vibration
• Withstand temperature excursions from -40°C to +70°C
• Fast recharge with no adverse effects
• Impervious to ripple (a VRLA killer)
• Low maintenance
• Low total cost of ownership
• Design and service Life 25+ years
Disadvantages
• High initial cost compared with lead-acid
• Installed footprint can be larger than lead acid in some applications

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 Nickel Cadmium Pocket Plate (traditional design)

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 Maintenance Free (Recombinant) NiCd

Maintenance-free L and M types

• Qualified IEC 62259 for Ni-Cd with gas recombination (over 97%)
• Electrolyte is still liquid and abundant inside.

High tech maintenance-free concept

• Maintenance-free
○ No requirement to add any water throughout service life under
recommended operations
○ Decrease the operational cost and reduce the maintenance manpower
○ Can be stored filled and charged up to 2 years

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 High Performance NiCad Batteries (S/PBE)

Sintered plate (Positive Plate)

Plastic Bonded Electrode (Negative Plate)

Highest Performance NiCad

• High Energy Density
• High Power
• High charge acceptance at low voltage
Ideal for Engine Starting and Switchgear
Applications
Low Maintenance
• 10 – 13 Year topping up interval
Single Cell / Compact Design

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 Sintered Plate Technology

Electrochemical Nickel powder is sintered

Perforated & nickel impregnation with onto the strip to form a
plated steel strip active material highly porous and
conductive structure.

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 Plastic Bonded Plate Technology

Perforated & nickel Pasting and drying of active

plated steel strip material embedded into
organic binder

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 BATTERY
COMPARISON

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Technology Physical Comparison

What to look for:

Technologies being compared
• Nickel-Cadmium Vs Flooded Lead-Acid (VLA)

Sizing Results

Comparison parameters
• Footprint
• Volume
• Total weight (battery + racking)
• Price

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Sizing Parameters

Parameters Load Profile

Min. Voltage: 105 Vdc Step Load Duration

1: 5A 8hr
Max. Voltage: 140 Vdc
2: 300 A 1 min*
Nom. Voltage: 125 Vdc
*For Nickel-Cadmium the
Design Margin: 1.15 minimum performance step is 1
sec Vs. 1 min for Lead-Acid
Aging Factor: 1.25 (Coup de Fouet).
The “tripping load” can occur in
Temperature (max): 30 °C under one second bursts.

Temperature (min): 15 °C

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Sizing Results

Nickel-Cadmium Vented Lead-Acid

Nominal Capacity: 130 Ah Nominal Capacity: 350Ah

Total WxDxH 59" x 28" x 68" Total WxDxH 83" x 28” x 71"

Total Weight: ~1,652 lbs Total Weight: ~4,461 lbs

Installed Energy: 16.3 kWh Installed Energy: 43.8 kWh

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Footprint Comparison

Li-ion
Ni-Cd
VLA

Technology W (in) D (in) Area (in²)

Ni-Cd 59 28 1,652
VLA 83 28 2,324

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Volume Comparison

Technology W (in) D (in) H (in)

Ni-Cd 59 28 68
VLA 83 28 71

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 Total Weight Comparison

Technology Weight (lbs)

Ni-Cd 1,652
VLA 4,461

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Price Comparison

Technology Initial Price

Ni-Cd $26k
VLA $14k

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 CHOOSING THE
RIGHT TECHNOLOGY

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 Considerations

 High Temperature

 Low Temperature

 Longer Life

 Low Maintenance

 Storage

 Space – Weight

 Vibration / Shock

 Cost of Failure

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 High Temperature – Shortens Life

Lead Acid
• Life is cut 50% for every 15°F
over 77°F
Nickel Cadmium
• Life is cut 20% for every 15°F
over 77°F
Normal Service Life
• VRLA 3 - 10 years
• Flooded Lead 12 – 15 years
• Ni-Cd 25+ years

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 Low Temperature – Reduces Performance

Available Capacity
120%
110% Sintered/PBE nickel-cadmium
100%
90%
Lead Acid
80%
70%
60% Pocket Plate nickel-cadmium
50%
-40 -30 -20 -10 0 10 20 30 40 50 60
Temperature °C

Nickel cadmium can operate to – 50C, no danger of freezing. Lead Acid can Freeze

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 Life Cycle Curve

120

100
% Capacity

80

60

40

20

0
0 20 30 40 50 60 70 80 90 100 110
% Life
Lead Nicad

• Ni-Cd cells loose about 1% capacity per year of life, they can continue service
after 25 years with no catastrophic failure and will not fail in open circuit.
• When lead acid cells fail, they fail abruptly
• Graph shows ideal environment, maintenance and operating parameters.

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 Maintenance

Why is it important?
• Secure and protect the battery investment
• Required for some applications (NERC/FERC)
• Predict failures
• Easy warranty claims
Must consider:
• Total cost of ownership
• Site location and accessibility

Maintenance IEEE 450 IEEE 1188 IEEE 1106

Procedures Lead Acid VRLA Nickel Cadmium
Visual inspection Monthly Monthly Quarterly
Pilot cell reading Monthly Monthly Quarterly
Float voltage – battery Monthly Monthly Quarterly
Float voltage – cells Quarterly Semi-annually Semi-annually
Watering 3-6 Months Never / replace 1.8 – 20 Years

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 Storage

How often do you hear, “The site is not ready.”

• Once filled, Lead Acid needs refreshing charge every 3-6 months
• Nickel Cadmium Pocket Plate (SBLE/SBM/SBH) can be stored for 6 months
to 1 year (filled and charged) or many years dry and discharged.
• Sintered Plastic Bonded Electrode (SPH) Cells can be stored discharged
for many years.
• Uptimax are supplied filled and charged and can be stored for 2 years in
this condition.
• Consider the battery’s DATE CODE!
• On-site commissioning is recommended for all batteries

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 Cost of failure

• Battery cost in relation to protected equipment cost is negligible.

• Loss of power could result in loss of thousands to millions of dollars or

even loss of life.

• Lead Batteries even when monitored and maintained can be

unpredictable as to when they will fail. Lead cells usually fail as an
open circuit. One lead-acid cell failure will take out whole battery.

• Nickel Cadmium have very gradual capacity loss. Ni-Cd cells fail
as a short circuit. The battery will still function with loss of several
cells.

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 Further References

• IEEE1106 – Recommended practice for Installation, Maintenance, Testing, and

replacement of Vented Nickel-Cadmium Batteries

• IEEE1115- Recommended Practice for Sizing Nickel-Cadmium batteries for

stationary applications

• IEEE 450 – Recommended practice for Maintenance, Testing and replacement

of Vented Lead-Acid Batteries

• IEEE484 – Recommended practice for Installation of Vented Lead-Acid

batteries

• IEEE485 – Recommended Practice for Sizing Lead-Acid batteries for stationary

applications

• IEEE1188 - Recommended practice for Installation, Maintenance, Testing, and

replacement of Valve Regulated Lead-Acid Batteries

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 Additional Saft Resources

Lunch and Learns

- Battery Sizing and Selection
- Advanced Nickel Cadmium Concepts
- Advanced Lithium-Ion Concepts
- Battery Chargers and other DC System Components

Guide Specifications for Consultants

Factory Battery Maintenance Training

Thank You . . . Questions??

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