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.
3. 3
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
4. WHAT’S A BATTERY?
a container consisting of one or more cells,
in which chemical energy is converted into
electricity and used as a source of power.
bat·ter·y
/ˈbatərē/
noun
4
5. WHAT’S A BATTERY?
Electrolytes allow ions to move between the electrodes, which
allows current to flow out of the battery to perform work.
5
8. WHAT’S A BATTERY?
Lower specific energy than common fuels.
Only energy type that delivers their energy as electricity.
Meaning they are efficiently converted to mechanical work.
8
10. 10
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
11. 11
CHANCES ARE…
The stats from our commercial telecom
customers are, on average:
• Number of outages: 4 outages per site per year
• Length of each outage: 1.5 hours
• Direct cost of losing a telecom site: $250,0001
• Indirect cost of losing a telecom site: $150,0001
• Direct cost of losing a substation’s protection: TBD2
• Indirect cost of losing a substation’s protection: TBD2
Note:
1: Direct and indirect costs attributed to a battery-related outage when a site was lost in Miami, FL by a major US telecom operator
2: “We don’t even want to image it” is more likely the answer…
12. MOREOVER…
3 things we know with absolute certainty about batteries:
(1) limited CAPACITY
(2) finite and unpredictable LIFETIME
(3) always fail EXACTLY when you need them
12
13. What are your chances of running on batteries?
I would say: PRETTY HIGH.
13
14. 14
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
15. TOP 10 #BATTERY_FAILS
10 - Prolonged period without being used
9 - Battery post corrosion, causing (dis)charge problems
8 - Excessive deep discharges
7 - Bad manufacturing process or material
6-Torquing: too much > break terminal seal, too little > short
15
16. TOP 10 #BATTERY_FAILS
5 -AC ripple (on UPS batteries)
4 - Lack of electrolyte (wet cell batteries)
3 - ↑25°C > corrosion > self discharge > thermal runaway
2 - Over-charging = creates heat = loss of water = sulfation
1 - Under-charging = electrolyte stratification
16
17. 17
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
20. WHY DO YOU NEED IT?
Because there can be up to 15 pieces of equipment making
for the “POWER-TRAIN”within a telecom site.
Because OUTAGES & EQUIPMENT MALFUNCTIONS happen.
Because it impacts you and your CUSTOMERS.
And because it’s EXPENSIVE.
20
29. 29
WHY DO YOU NEED IT?
A few stats on availability or poor backup management:
• 99.9% (Three Nines) availability = 9 hrs/year of downtime.1
• 99.9999% (Six Nines) availability = 30 seconds/year of downtime.2
• 1 hour of downtime equates to $2.0M/hour in the telecom industry.3
• It’s terrible for your customers: $1.4 million/hour to financial institutions.3
• $80B: the amount of yearly losses due to power disturbances in the US.
66% of that caused by momentary disturbances, 34% caused by sustained
interruptions of more than 5 minutes.4
References:
1: GilderGroup
2: The dawn of on-site power: http://ecmweb.com/cee-news-archive/dawn-site-power
3: Overhead: The cost of downtime: http://itknowledgeexchange.techtarget.com/overheard/overhead-the-cost-of-downtime/
4: Berkeley Lab Study Estimates $80 Billion Annual Cost of Power Interruptions: http://www.lbl.gov/Science-Articles/Archive/EETD-power-interruptions.html
31. 31
The questions you need to ask:
• How much time do you need?
• How much time do you really have?
• In what state of health is your backup?
• Can you consistently meet your average failure?
• What happens if your backup doesn’t work?
32. So, let’s see what the role of Field Operations
is when it comes to battery backup.
32
33. 33
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
34. Field Maintenance and Operations teams are typically
responsible for two aspects of battery backup:
MAINTENANCE ROUTINES & OUTAGE INTERVENTION.
34
35. 35
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
36. MAINTENANCE ROUTINES
The two reasons why you do battery preventative
maintenance routines are:
BATTERIES WILL FAIL & NERC COMPLIANCY.
36
38. NERC COMPLIANCY
NERC has multiple RELIABILITY STANDARDS.
One of them is PRC-005-2, which will be enforced starting April
1, 2015, but should have been used starting February 24, 2014.
It covers the MAINTENANCE of all Protection Systems affecting
the reliability of the Bulk Electric System (BES) so that these
Protection Systems are kept in working order.
38
39. NERC COMPLIANCY
Basically, it tells you what tests & time intervals
to follow for your BATTERY MAINTENANCE.
It is applicable to both protection relays &
TELECOMMUNICATIONS SITES.
39
40. NERC COMPLIANCY
Maximum
Maintenance Interval
Maintenance Activity VLA (wet cell) VRLA
4 Calendar Months
Verify
• Station DC supply voltage
Inspect
• Electrolyte level
• For unintentional grounds
✓ ✓
6 Calendar Months
Inspect
• Measure battery cell internal ohmic
values for each battery cells
✓
18 Calendar Months
Verify
• Float voltage of battery charger
• Battery continuity
• Battery terminal connection resistance
• Battery intercell or unit-to-unit
connection resistance
Inspect
• Cell condition of all battery cells (visible
cells) or measure battery cell internal
ohmic values (not visible cells)
• Physical condition of battery rack
✓ ✓
18 Calendar Months
or
6 Calendar Years
Verify
• Internal ohmic values or float current
per cell compared to baseline
or
Verify
• Full or modified capacity (discharge,
load) test on the entire battery bank
✓
✓
But every 3 years for
the capacity test
40
41. NERC COMPLIANCY
If, like most companies, you have VRLAs, you need
to test your batteries EVERY 6 MONTHS using an
ohmic test (conductance, impedance).
And you have to demonstrate COMPLIANCY…
41
44. PSMP
Always refer to your
Protection System Maintenance Program
Start Here
Ticket
A technician will typically receive
an automated ticket to perform a
maintenance routine
44
45. PSMP
Always refer to your
Protection System Maintenance Program
Start Here
Ticket
A technician will typically receive
an automated ticket to perform a
maintenance routine
Plan Workload
A technician will typically receive
an automated ticket to perform a
maintenance routine
45
46. PSMP
Always refer to your
Protection System Maintenance Program
Start Here
Ticket
A technician will typically receive
an automated ticket to perform a
maintenance routine
Plan Workload
A technician will typically receive
an automated ticket to perform a
maintenance routine
Execute Routine
A technician will typically receive an
automated ticket to perform a
maintenance routine
46
47. ROUTINE EXECUTION
1
- Use the turkey baster to measure the specific gravity of each cell. There’s a big drawback: you need protective gear.
Test specific gravity of each wet cells’ jars
47
49. ROUTINE EXECUTION
1
2 Visual inspection of each battery jar and battery rack
- Use the turkey baster to measure the specific gravity of each cell. There’s a big drawback: you need protective gear.
Test specific gravity of each wet cells’ jars
- Get a flashlight and look for bottom jar’s sediment, warping of place, cracked or broken plates, seeping of acid
around the posts, acid leakage at the bottom of the rack, installation issues, electrolyte level for wet cells…
49
60. ROUTINE EXECUTION
1
2 Visual inspection of each battery jar and battery rack
- Use the turkey baster to measure the specific gravity of each cell. There’s a big drawback: you need protective gear.
Test specific gravity of each wet cells’ jars
- Get a flashlight and look for bottom jar’s sediment, warping of place, cracked or broken plates, seeping of acid
around the posts, acid leakage at the bottom of the rack, installation issues, electrolyte level for wet cells…
3 Full or modified capacity test (aka discharge/load)
- Get a load bank & volt meter. As the battery is discharging, you want to take voltage reading of each jar, and at the power
plant level, at specific time intervals. Your goal is to measure the time it will take to reach your end-voltage threshold.
60
61. CAPACITY TEST
Capacity test procedure for wet cell (VLA)
batteries is detailed in IEEE Standard 450-2010.
Capacity test procedure for VRLA batteries is
details in IEEE Standard 1188-2005.
61
62. CAPACITY TEST
PROS CONS
• Definitive test to measure
your battery reserve time
• Takes time & is relatively expensive
• Need a load bank
• It’s relatively technical and requires a high
level of security & training, dangerous for
people without proper training
• It damages the battery
• Two plates push electrons from one plate to the other.
• The more you do it, the more porous the plates become.
62
64. ROUTINE EXECUTION
1
2 Visual inspection of each battery jar and battery rack
- Use the turkey baster to measure the specific gravity of each cell. There’s a big drawback: you need protective gear.
Test specific gravity of each wet cells’ jars
- Get a flashlight and look for bottom jar’s sediment, warping of place, cracked or broken plates, seeping of acid
around the posts, acid leakage at the bottom of the rack, installation issues, electrolyte level for wet cells…
3 Full or modified capacity test (aka discharge/load)
- Get a load bank & volt meter. As the battery is discharging, you want to take voltage reading of each jar, and at the power
plant level, at specific time intervals. Your goal is to measure the time it will take to reach your end-voltage threshold.
4 Manual or automated ohmic test
- Manual using a portable ohmic testing device, or automated using a battery monitoring system.
64
65.
66. German physicist.
High school teacher.
Began his research with a recent
invention by Italian Count
Alessandro Volta.
Using equipment of his creation, he
determined that there is a:
direct proportionality between the
potential difference applied across a
conductor and the resultant electric
current.
66
68. OHM’S LAW
Ohm's law states that the
current through a conductor
between two points is
directly proportional to the
potential difference across
the two points, and inversely
proportional to the
resistance between them.
68
69. CONDUCTANCE
Conductance is a measurement of the plate surfaces available for
chemical reaction. High relative conductance is a reliable indication of a
healthy battery. Conductance declines as the battery fails.
By applying an electrical voltage of a known frequency and amplitude
across the jar and measuring the current that flows in response to it.The
conductance (acceptance) is the ratio of the AC test current impressed on
the jar that is in-phase with the AC voltage, compared to the AC voltage
producing it.
DC Resistance: Short duration DC load on the cell/unit to measure step
change in current and voltage. By dividing the change in voltage by the
change in current, a DC resistance is calculated using Ohm's law.
69
70. IMPEDANCE
Performed by sending an electrical current of a known frequency and
amplitude, across the cell/unit/block and measuring the AC voltage drop.
Compute the resulting impedance using Ohm's law.
70
72. OHMIC TEST
Ohmic test procedure for wet cell (VLA) batteries
is detailed in IEEE Standard 450-2010.
Ohmic test procedure for VRLA batteries is
details in IEEE Standard 1188-2005.
72
74. BATTERY MONITOR
You can automate ohmic testing using a
battery monitoring system.
Even if the cost is high (~$2,500 per site), the ability
to catch a battery before it fails outpace its cost.
Selection and use of a battery monitoring system is
detailed in IEEE Standard 1491-2005.
74
75. OHMIC TEST
PROS CONS
• Non-intrusive
• No torquing required as you test the
intercell straps
• Quicker & safer than a capacity test
• Standardized w/ choice of equipment
out there
• Statistically-proven relationship
between ohmic & capacity as tested
by discharge
• Good way to test that a new battery is
good & creating a baseline
• Rapid way of tracking relative health
& identifying jars/batteries that fail
prematurely
• General agreement that it is not
as definitive as capacity test…
• % of negative-pass
• Some statistical anomalies that can cloud
results
• Make sure you have the right
reference value when analyzing
test results
75
76. ROUTINE EXECUTION
1
2 Visual inspection of each battery jar and battery rack
- Use the turkey baster to measure the specific gravity of each cell. There’s a big drawback: you need protective gear.
Test specific gravity of each wet cells’ jars
- Get a flashlight and look for bottom jar’s sediment, warping of place, cracked or broken plates, seeping of acid
around the posts, acid leakage at the bottom of the rack, installation issues, electrolyte level for wet cells…
3 Full or modified capacity test (aka discharge/load)
- Get a load bank & volt meter. As the battery is discharging, you want to take voltage reading of each jar, and at the power
plant level, at specific time intervals. Your goal is to measure the time it will take to reach your end-voltage threshold.
4 Manual or automated ohmic test
- Manual using a portable ohmic testing device, or automated using a battery monitoring system.
76
77. A 5FT “TEST”…
If you didn’t upgrade your power plant to an intelligent
one, you should EQUALIZE your batteries, by making
sure float voltage is at the right value for each jar.
77
78. PSMP
Always refer to your
Protection System Maintenance Program
Start Here
Ticket
A technician will typically receive
an automated ticket to perform a
maintenance routine
Plan Workload
A technician will typically receive
an automated ticket to perform a
maintenance routine
Execute Routine
A technician will typically receive an
automated ticket to perform a
maintenance routine
Continue Here
Review
Tech’s live review & analysis of
test data
78
80. PSMP
Always refer to your
Protection System Maintenance Program
Start Here
Ticket
A technician will typically receive
an automated ticket to perform a
maintenance routine
Plan Workload
A technician will typically receive
an automated ticket to perform a
maintenance routine
Execute Routine
A technician will typically receive an
automated ticket to perform a
maintenance routine
Continue Here
Review
Tech’s live review & analysis of
test data
Close Routine
Complete & close PM ticket
80
81. PSMP
Always refer to your
Protection System Maintenance Program
Start Here
Ticket
A technician will typically receive
an automated ticket to perform a
maintenance routine
Plan Workload
A technician will typically receive
an automated ticket to perform a
maintenance routine
Execute Routine
A technician will typically receive an
automated ticket to perform a
maintenance routine
Continue Here
Review
Tech’s live review & analysis of
test data
Close Routine
Complete & close PM ticket
Send to Eng.
Email test results to engineering
for further analysis & replacement
request form filled-out if need be
81
82. PSMP
Always refer to your
Protection System Maintenance Program
Start Here
Ticket
A technician will typically receive
an automated ticket to perform a
maintenance routine
Plan Workload
A technician will typically receive
an automated ticket to perform a
maintenance routine
Execute Routine
A technician will typically receive an
automated ticket to perform a
maintenance routine
Continue Here
Review
Tech’s live review & analysis of
test data
Close Routine
Complete & close PM ticket
Send to Eng.
Email test results to engineering
for further analysis & replacement
request form filled-out if need be
Engineering
Takes Over
• Approve/refuse replacement
• Crunch test data and load in
central repository
• Provide metrics for NERC’s
compliancy
82
83. 83
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
87. Alarm to NOC
NOC received “Battery On
Discharge” & other alarms
Start Here
Dispatch
NOC will dispatch closest
technician to site
87
88. Alarm to NOC
NOC received “Battery On
Discharge” & other alarms
Start Here
Dispatch
NOC will dispatch closest
technician to site
Validate ETA
If not done by NOC, a tech will
validate the cause of outage, length
& ETA to restore
88
89. Alarm to NOC
NOC received “Battery On
Discharge” & other alarms
Start Here
Dispatch
NOC will dispatch closest
technician to site
Validate ETA
If not done by NOC, a tech will
validate the cause of outage, length
& ETA to restore
Validate BRT
Based on outage information,
technician will validate the estimated
battery reserve time (BRT) on site
89
90. AS A RULE OF THUMB
Validated ETA - Validated BRT
= Time to get to a site & react/repair
90
91. VALIDATE BRT
A validated Battery Reserve Time (BRT) is a key metric
field technicians need to react in optimal fashion in
case of outage or equipment failure.
• Get there as soon as necessary
• Bring the right equipment (generator, generator
connector fitting plug and cable, replacement parts)
• Do as few truck rolls as possible
• Keep the site up
91
92. VALIDATE BRT
There are 4 steps needed to validate BRT:
(1) look for the last available LOAD reading
(2) look for records of exact battery MODEL installed on site
(3) find battery model’s DATASHEET with specific capacity
measurements at specific end-voltage value
(4) use rule of thumb or PEUKERT to estimate BRT
92
93.
94. German scientist.
In 1897, presented his “law” that
expresses the capacity of a battery
in terms of the rate at which it is
discharged.
As the rate increases, the battery's
available capacity decreases.
94
96. PEUKERT
Manufacturers rate the capacity of a battery with reference
to a discharge time.A battery might be rated at 100 Ah
when discharged at a rate that will fully discharge the
battery in 20 hours. In this example, the discharge current
would be 5 amperes. If the battery is discharged in a shorter
time, with a higher current, the delivered capacity is less.
96
97. PEUKERT
What you need to know:
(1) The law is not a law, it’s a recognized concept.
(2) Peukert determines a “k” factor to apply to a battery
technology. For telecom batteries: 1.2.
97
100. Alarm to NOC
NOC received “Battery On
Discharge” & other alarms
Start Here
Dispatch
NOC will dispatch closest
technician to site
Validate ETA
If not done by NOC, a tech will
validate the cause of outage, length
& ETA to restore
Validate BRT
Based on outage information,
technician will validate the estimated
battery reserve time (BRT) on site
Continue Here
Truck Roll
Get all you need and get to the
site
100
101. Alarm to NOC
NOC received “Battery On
Discharge” & other alarms
Start Here
Dispatch
NOC will dispatch closest
technician to site
Validate ETA
If not done by NOC, a tech will
validate the cause of outage, length
& ETA to restore
Validate BRT
Based on outage information,
technician will validate the estimated
battery reserve time (BRT) on site
Continue Here
Truck Roll
Get all you need and get to the
site
Repair
Proceed with repair or hook-up
generator
101
102. Alarm to NOC
NOC received “Battery On
Discharge” & other alarms
Start Here
Dispatch
NOC will dispatch closest
technician to site
Validate ETA
If not done by NOC, a tech will
validate the cause of outage, length
& ETA to restore
Validate BRT
Based on outage information,
technician will validate the estimated
battery reserve time (BRT) on site
Continue Here
Truck Roll
Get all you need and get to the
site
Repair
Proceed with repair or hook-up
generator
Turn On Power
Once repaired, or AC is back on,
switch off generator and go back to
commercial power
102
103. Alarm to NOC
NOC received “Battery On
Discharge” & other alarms
Start Here
Dispatch
NOC will dispatch closest
technician to site
Validate ETA
If not done by NOC, a tech will
validate the cause of outage, length
& ETA to restore
Validate BRT
Based on outage information,
technician will validate the estimated
battery reserve time (BRT) on site
Continue Here
Truck Roll
Get all you need and get to the
site
Repair
Proceed with repair or hook-up
generator
Turn On Power
Once repaired, or AC is back on,
switch off generator and go back to
commercial power
Wait!!!!!
• Make sure you have enough
charger capacity to manage:
• in-rush current
• recharge batteries
• carry the DC load
• hope the batteries are recharged
before power goes out again…
• … all at the same time
103
104. You’ve just glanced at what a technicians needs
to know when it comes to battery backup…
And you thought engineers had it hard!?
104
105. 105
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
106. Engineering teams are typically responsible
for two aspects of battery backup:
PLANNING/SIZING & REPLACING.
106
107. 107
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
108. PLANNING
When planning new projects in new or existing sites,
engineering needs to RIGHT-SIZE the batteries to be deployed.
Let’s see what that means.
108
110. Project Issued
Once strategic engineering is
done & funding approved
Start Here
Estimate Load
Look for the THEORETICAL DC
load of new equipment
110
111. Project Issued
Once strategic engineering is
done & funding approved
Start Here
Estimate Load
Look for the THEORETICAL DC
load of new equipment
Challenge That
Theoretical loads will always vary,
typically they are inflated. Agree on
a maximum load
111
112. Project Issued
Once strategic engineering is
done & funding approved
Start Here
Estimate Load
Look for the THEORETICAL DC
load of new equipment
Challenge That
Theoretical loads will always vary,
typically they are inflated. Agree on
a maximum load
Pick Site Type
The type of site you pick with have a
huge influence on the battery
solution you end up with
112
113. PICK SITE TYPE
Two important aspects to site type:
(1) Available FLOOR SPACE (2) FLOOR LOADING capacity
Large site Small site
Wet cell VRLA
300 lbs/sq.ft 125 lbs/sq.ft
Wet cell VRLA
113
114. Project Issued
Once strategic engineering is
done & funding approved
Start Here
Estimate Load
Look for the THEORETICAL DC
load of new equipment
Challenge That
Theoretical loads will always vary,
typically they are inflated. Agree on
a maximum load
Pick Site Type
The type of site you pick with have a
huge influence on the battery
solution you end up with
Continue Here
Pick Battery
Pick the battery solution &
model you want in your site
114
115. PICK BATTERY
There are two battery technologies to pick from:
WET CELL (VLA) & VRLA.
115
116. PICK BATTERY
WET CELL (VLA) VRLA
• Proven since…
>100 years
• Robust
• Reliable
• Recover well
• Long lifetime
Pros Cons
• Acid!!!
• Lead!!
• Takes space
• Heavy
• Requires “maintenance”
• Produces hydrogen gas
during charging
• Needs hydrogen sensor,
proper ventilation &
equipment in battery
room
• Small & portable
• Easier to install
• Can fit anywhere
• Lighter
• Requires no “dangerous”
maintenance
• Shorter lifetime
• Smaller value
over the long run
• Higher risks of
thermal runaway
ConsPros
116
117. PICK BATTERY
Before picking a battery manufacturer & model, check
with your STANDARDS group or TECHNOLOGY ADVISOR,
they typically have a few selections they want you to use.
117
118. Project Issued
Once strategic engineering is
done & funding approved
Start Here
Estimate Load
Look for the THEORETICAL DC
load of new equipment
Challenge That
Theoretical loads will always vary,
typically they are inflated. Agree on
a maximum load
Pick Site Type
The type of site you pick with have a
huge influence on the battery
solution you end up with
Continue Here
Pick Battery
Pick the battery solution &
model you want in your site
Find Specs
Use the battery manufacturer
spec sheet to decide which
capacity version you need
118
119. FIND SPECS
Each battery model has a specific capacity value for
specific end-voltage designs. It’s the engineer’s job to
make sure he designs with the right specs.
119
120. FIND SPECS
Each battery model has a specific NOMINAL CAPACITY
rating (in Ah) for specific END-VOLTAGE designs, for a
REQUIRED RESERVE TIME duration.
It’s the engineer’s job to make sure he designs with
the right specs.
120
124. Project Issued
Once strategic engineering is
done & funding approved
Start Here
Estimate Load
Look for the THEORETICAL DC
load of new equipment
Challenge That
Theoretical loads will always vary,
typically they are inflated. Agree on
a maximum load
Pick Site Type
The type of site you pick with have a
huge influence on the battery
solution you end up with
Continue Here
Pick Battery
Pick the battery solution &
model you want in your site
Find Specs
Use the battery manufacturer
spec sheet to decide which
capacity version you need
Size
After picking a model, you now
need to decide on the quantity
needed to support your load
124
126. SIZE
BUT…
You need to provision for growth @ battery end of life.
The reality of telecom facilities is that they change.
New technologies get added, load will vary. You need to
provision for that from day one.
126
127. SIZE
Total Projected Load ➗ Nominal Capacity Specs of chosen model
= THE NUMBER OF STRINGS NEEDED OF THAT MODEL
127
128. SIZE - EXAMPLE
Projected Load (A) 100
Battery Model Specs (Ah)
(Enersys SBS170F @ 1.75Vpc @ 8hours)
21.6
Number of Strings Needed 4.6
Note: Some people add an aging factor, like 1.25, to the
number of strings needed. You don’t have to, but you can if you
feel you have the money or your projected load is not relevant.
128
129. Project Issued
Once strategic engineering is
done & funding approved
Start Here
Estimate Load
Look for the THEORETICAL DC
load of new equipment
Challenge That
Theoretical loads will always vary,
typically they are inflated. Agree on
a maximum load
Pick Site Type
The type of site you pick with have a
huge influence on the battery
solution you end up with
Continue Here
Pick Battery
Pick the battery solution &
model you want in your site
Find Specs
Use the battery manufacturer
spec sheet to decide which
capacity version you need
Size
After picking a model, you now
need to decide on the quantity
needed to support your load
Issue Install &
Project Request
• Once the project is sent out:
• make sure you wait until the project
is completed before updating records,
in case of outage
• don’t forget to update records with
new battery model & information
• make sure technicians know the
ohmic reference value for that model
129
130. 130
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
131. REPLACING
Based on Murphy’s law, if you have bad
batteries, even if you did everything else
right, for sure,THAT ONE SITE WILL FAIL.
Replacing a battery is as important as installing a new one.
131
132. Get Data
Get test data from field
technicians at regular intervals
Start Here
132
133. Get Data
Get test data from field
technicians at regular intervals
Start Here
Analyze Data
Look for the THEORETICAL DC
load of new equipment
133
134. ANALYZE DATA
The data you’ll receive from field technicians is the only &
best metric you have to make a decision to maximize
uptime. It’s important, don’t just file it without looking at it.
134
135. ANALYZE DATA
Things to look for:
(1) Has the load reading changed since last time?
(2) Was the temperature in the site constant at 25°C?
(3) Is the float voltage of the jars and strings at the right value?
> Remotely connect to the controller to make sure. <
(4) Where are the ohmic test results compared to the reference?
135
136. OHMIC REFERENCE
The ohmic reference value is a hot topic:
(1) Do not trust the reference value the tech was using.
(2) Ideally, have each new string benchmarked at 6 months.
(3) Get the reference from the battery manufacturer.
Don’t use it just yet.
(4) Get reference value from Midtronics or other equipment
vendors. Use this one if it’s slightly lower than the mfg’s.
(5) Repeat for each of your sites.
136
137. OHMIC REFERENCE
At which reference value should you REPLACE?
Status
Conductance
Reference
Impedance
Reference
Jars are GOOD when > = 80% < = 70%
Jars are WARNING when < 80% and > = 60% > 70% and < = 90%
Jars are BAD when < 60% > 90%
137
138. Get Data
Get test data from field
technicians at regular intervals
Start Here
Analyze Data
Look for the THEORETICAL DC
load of new equipment
No Data = Age
For the sites for which you didn’t
get data in the past 24 months, use
age as your replacement trigger
138
139. NO DATA
What do you do if you do not have data?
(1) Don’t even try hiding it from NERC.
(2) Use age as your replacement trigger.
(3) Send a tech as fast as you can to inspect & measure.
139
140. Get Data
Get test data from field
technicians at regular intervals
Start Here
Analyze Data
Look for the THEORETICAL DC
load of new equipment
No Data = Age
For the sites for which you didn’t
get data in the past 24 months, use
age as your replacement trigger
Replacement List
Build a replacement list based on all
the data files you received.
140
141. REPLACEMENT LIST
What do you do if you do not have data?
(1) Don’t even try hiding it from NERC.
(2) Use age as your replacement trigger.
(3) Send a tech as fast as you can to inspect & measure.
141
142. Get Data
Get test data from field
technicians at regular intervals
Start Here
Analyze Data
Look for the THEORETICAL DC
load of new equipment
No Data = Age
For the sites for which you didn’t
get data in the past 24 months, use
age as your replacement trigger
Replacement List
Build a replacement list based on all
the data files you received.
Continue Here
Recalculate BRT
When you received your test results,
you also go a new DC load reading
142
143. RECALCULATE BRT
Ohmic test results can be
represented a % of your reference.
Can you use that % as a de-rating
factor to reduce battery capacity?
143
147. RECALCULATE BRT
When you got your test data back from field
operations, you also got an updated DC load reading.
If it changed, use the new value to recalculate your
updated Battery Reserve Time (BRT).
147
148. Get Data
Get test data from field
technicians at regular intervals
Start Here
Analyze Data
Look for the THEORETICAL DC
load of new equipment
No Data = Age
For the sites for which you didn’t
get data in the past 24 months, use
age as your replacement trigger
Replacement List
Build a replacement list based on SOH
& age
Continue Here
Recalculate BRT
When you received your test results,
you also go a new DC load reading
Repeat
Don’t forget to repeat this for
each site in your network
148
149. Get Data
Get test data from field
technicians at regular intervals
Start Here
Analyze Data
Look for the THEORETICAL DC
load of new equipment
No Data = Age
For the sites for which you didn’t
get data in the past 24 months, use
age as your replacement trigger
Replacement List
Build a replacement list based on SOH
& age
Continue Here
Recalculate BRT
When you received your test results,
you also go a new DC load reading
Repeat
Don’t forget to repeat this for
each site in your network
BRT List
For any site lacking BRT, create a
list to add battery capacity
149
150. BRT LIST
Build a list of all the sites that require added
batteries to support:
(1) De-rated capacity based on ohmic test results
(2) Updated DC load reading
150
151. Get Data
Get test data from field
technicians at regular intervals
Start Here
Analyze Data
Look for the THEORETICAL DC
load of new equipment
No Data = Age
For the sites for which you didn’t
get data in the past 24 months, use
age as your replacement trigger
Replacement List
Build a replacement list based on SOH
& age
Continue Here
Recalculate BRT
When you received your test results,
you also go a new DC load reading
Repeat
Don’t forget to repeat this for
each site in your network
BRT List
For any site lacking BRT, create a
list to add battery capacity
Cross Reference
Both Lists to
Create Projects
• You end up with two
replacement lists, based on:
• Ohmic state-of-health (SOH) & age
• De-rated capacity & updated load
• Cross-reference to:
• Prioritize replacement needs
• Preventing mistakes such as adding
capacity when you should install new
model
151
152. So, who has the toughest job?
FIELD TECHNICIANS or ENGINEERS?
152
153. My point: to maximize battery backup & uptime,
you need both teams to work in full cooperation.
It’s a question of COMMUNICATION & CULTURE.
Promoting this should be a high priority…
Everything else is a process.
153
154. 154
➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
155. EXTEND LIFETIME
My conclusion today: what can you do to help
extend the lifetime of your batteries?
(4) Top wet cells up in the spring.
(3) Never discharge them… hahaha!
(2) 25°C all the time
(1) Float them at the right voltage
155
156. ➡ DISCLAIMER
➡ INTRODUCTION
➡ WHAT IS A BATTERY?
➡ WHAT ARE YOUR CHANCES OF RUNNING ON BATTERIES?
➡ WHY DO BATTERIES FAIL?
➡ WHY DO YOU NEED IT?
➡ BATTERY BACKUP: FIELD OPERATIONS
➡ PREVENTIVE MAINTENANCE
➡ OUTAGE INTERVENTION
➡ BATTERY BACKUP: ENGINEERING PERSPECTIVE
➡ PLANNING NEW PROJECTS
➡ REPLACING OLD OR EXISTING PROJECTS
➡ CONCLUSION
➡ SHAMELESS PLUG & FREEBIE
157. We’re at > 150 slides. It’s a little overwhelming.
159. At Multitel, we’ve developed a tool that’s AUTOMATING
most of the processes & steps you’ve seen here today.
FIRM Battery Management
It’s the first enterprise software that gives snapshot &
detailed views of your at risk sites when it comes to batteries.
160. 1
2
4 6
3
5
1. # of routines completed for the network, per
region, per technician
2. # of cells failed or failing based on impedance
3. # of cells failed or failing based on conductance
From the Dashboard, you have access to:
4. List of sites with problems that need escalation
5. List of routines w/ problem or warnings needing approval
6. List of sites for which technicians did an inventory change
requiring approval before being updated in FIRM
160
161. Through a simple interface, it helps field
technicians quickly upload test data.
And crunches it automatically to
generate prioritized replacement lists.
Saving engineers valuable time.
164. No matter who you are in the company, no matter the event, no
matter where you are: always know the updated reserve time
in each site within the network.
165. FREEBIE
Come see us at booth #308 to learn more about FIRM
Battery Management and we’ll show you the Top 10 Best
& Worst battery models for both Wet Cells & VRLAs.
166. Data analytics - always know which batteries are best or worst
performing within your network, drill to understand more.
Worst 10 models Worst failures rates Worst production years
167. May
5-‐8,
2015
|
Atlanta,
GA
|
www.utctelecom.org
Dakx Turcotte
Mobile: +1-418-262-0575
Email: dakx.turcotte@multitel.com
Booth # 903