UTC Telecom & Technology 2015 - Battery Backup Workshop
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Transcript of UTC Telecom & Technology 2015 - Battery Backup Workshop
© 2013 Utilities Telecom Council
May 5-‐8, 2015 | Atlanta, GA | www.utctelecom.org
BATTERY BACKUP WORKSHOP MAY 5, 2015
NO POWER=NO SERVICEDAKX TURCOTTE
MULTITEL INC.
DISCLAIMER
From concept to more practical & technical content.
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➡ 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
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
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WHAT’S A BATTERY?
Electrolytes allow ions to move between the electrodes, which allows current to flow out of the battery to perform work.
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WHAT’S A BATTERY?
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WHAT’S A BATTERY?
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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.
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WHAT’S A BATTERY?
Wet cell (VLA) jar VRLA jar Battery string/bank
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➡ 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
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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…
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
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What are your chances of running on batteries? I would say: PRETTY HIGH.
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➡ 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
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
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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
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➡ 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
WHY DO YOU NEED IT?
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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.
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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
It’s clear, YOU NEED BATTERIES.
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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?
So, let’s see what the role of Field Operations is when it comes to battery backup.
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➡ 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
Field Maintenance and Operations teams are typically responsible for two aspects of battery backup:
MAINTENANCE ROUTINES & OUTAGE INTERVENTION.
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➡ 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
MAINTENANCE ROUTINES
The two reasons why you do battery preventative maintenance routines are:
BATTERIES WILL FAIL & NERC COMPLIANCY.
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NERC COMPLIANCY
What is NERC COMPLIANCY?
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NERC COMPLIANCYNERC 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.
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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.
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NERC COMPLIANCYMaximum
Maintenance IntervalMaintenance Activity VLA (wet cell) VRLA
4 Calendar Months
Verify • Station DC supply voltage
Inspect • Electrolyte level • For unintentional grounds
✓ ✓
6 Calendar MonthsInspect • 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
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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…
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What’s a test procedure like?
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PSMP Always refer to your
Protection System Maintenance Program
Start Here
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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
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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
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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
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ROUTINE EXECUTION1
- 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
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SPECIFIC GRAVITY
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ROUTINE EXECUTION1
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…
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ROUTINE EXECUTION1
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.
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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.
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CAPACITY TESTPROS 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.
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ROUTINE EXECUTION1
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.
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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.
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Who is
Georg Simon Ohm (17 March 1789 – 6 July 1854)
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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.
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CONDUCTANCEConductance 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.
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IMPEDANCEPerformed 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.
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CONDUCTANCE VS. IMPEDANCE
Conductance - Decreases with battery age
Impedance - Increases with battery age
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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.
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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.
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OHMIC TESTPROS 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
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ROUTINE EXECUTION1
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.
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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.
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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
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TEST DATA REVIEW
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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
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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
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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
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➡ 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
OUTAGE INTERVENTION
Field technicians are the first people to be called/dispatched in case of:
MAIN POWER OUTAGE & POWER EQUIPMENT FAILURE.
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Alarm to NOC NOC received “Battery On Discharge” & other alarms
Start Here
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ALARM
There are typically 2 events that will trigger a BOD alarm: AC FAIL & CHARGER FAIL.
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Alarm to NOC NOC received “Battery On Discharge” & other alarms
Start Here
Dispatch NOC will dispatch closest
technician to site
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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
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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
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AS A RULE OF THUMB
Validated ETA - Validated BRT
= Time to get to a site & react/repair
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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
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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
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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.
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Who is Peukert
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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.
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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.
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PEUKERT
The law:
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PEUKERTUse a form!!!
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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
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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
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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
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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
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You’ve just glanced at what a technicians needs to know when it comes to battery backup… And you thought engineers had it hard!?
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➡ 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
Engineering teams are typically responsible for two aspects of battery backup: PLANNING/SIZING & REPLACING.
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➡ 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
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.
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Project Issued Once strategic engineering is
done & funding approved
Start Here
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Project Issued Once strategic engineering is
done & funding approved
Start Here
Estimate Load Look for the THEORETICAL DC
load of new equipment
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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
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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
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PICK SITE TYPETwo 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
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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
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PICK BATTERY
There are two battery technologies to pick from: WET CELL (VLA) & VRLA.
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PICK BATTERYWET 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
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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.
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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
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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.
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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.
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FIND SPECS
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FIND SPECS
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FIND SPECS
123
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
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SIZE
You’re almost there. You know which model you want to pick & you know your load. BUT…
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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.
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SIZE
Total Projected Load ➗ Nominal Capacity Specs of chosen model
= THE NUMBER OF STRINGS NEEDED OF THAT MODEL
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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.
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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
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➡ 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
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.
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Get Data Get test data from field
technicians at regular intervals
Start Here
132
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
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.
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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
OHMIC REFERENCEThe 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.
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OHMIC REFERENCEAt 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%
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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
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
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.
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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
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
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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
RECALCULATE BRT
Yes.
144
RECALCULATE BRT
145
RECALCULATE BRT
146
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
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
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
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
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
So, who has the toughest job? FIELD TECHNICIANS or ENGINEERS?
152
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
➡ 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
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
➡ 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
We’re at > 150 slides. It’s a little overwhelming.
KEEP CALM AND
HAVE ENOUGH
BACKUP
At Multitel, we’ve developed a tool that’s AUTOMATING most of the processes & steps you’ve seen here today.
FIRM Battery ManagementIt’s the first enterprise software that gives snapshot &
detailed views of your at risk sites when it comes to batteries.
12
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
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.
Complete battery replacement program.
And automatically updates Battery Reserve Time (BRT).
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.
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.
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
May 5-‐8, 2015 | Atlanta, GA | www.utctelecom.org
Dakx Turcotte Mobile: +1-418-262-0575
Email: [email protected]
Booth # 903