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    20 views11 pages

    Intelec 1993 - Field and Lab Studies

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    gustavo R
    intelec interessante

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    © All Rights Reserved
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    Intelec ‘93: Field and Laboratory Studies to Access the State-of-Health | of Valve-Regulated Lead-Acid and Other Battery Technologies Using Conductance Testing Part II - Further Conductance/Capacity Correlation Studies - Sept. 1993 Copy of Paper Presented to: nteLec 93 Paris, France September 27-30, 1993 Field and Laboratory Studies to Assess the State-of-Health of Valve-Regulated Lead Acid | and Other Battery Technologies: Using Conductance Testing Part I: Further Conductance/Capacity Correlation Studies eae % i by: Mark J. Hlavac Midtronics, Inc. Dr. David O. Feder Electrochemical Energy Storage Systems Inc. Madison, New Jersey, USA Thomas G. Croda Sprint Communications, San Mateo, California, USA Dr. Keith M. Champlin University of Minnesota, St-Paul, Minnesota, USA MIDTRONICS Midtronics, Inc. Midtronics bv. 15th International 8230 S. Madison Street Noord Wsseldijk 24 Ef ® . Burr Ridge, linois 60521 3402 PH-Weistein _ Telecommunications usa. ‘The Netherlands Tek: (630) 323-2800 Tel: 431 306 873 100 é Energy Conference Fax: (630) 323-2844 Fax: +31 306 889 015 SUES Field and Laboratory Studies to Assess the State-of-Health of Valve-Regulated Lead Acid and Other Battery Technologies Using Conductance Testing. PART Il: Further Conductance/Capacity Correlation Studies Etudes de Vieillissement de Batteries Etanches et D'autres Batteries au Plomb en Utilisant la Technique de la Conductance. PARTIE Il: Etudes Prolongées de la Conductance/Capacité Mark J. Hlavac Midtronics, Inc. Mark J. Hlavac Midtronics, inc. Je Dr, David O, Feder Electrochemical Energy Storage Systems, Inc., Madison, New Jersey, USA ‘Dr. David O, Feder Electrochemical Energy Storage Systems, inc., Madison, New Jersey, USA ‘Thomas G. Croda Thomas G. Croda ‘Sprint Communications, San Mateo, ‘Sprint Communications, San Mateo, Califomia USA Calitomia USA Dr. Keith S. Champlin University of Minnesota, Minneapolis, Minnesota, USA. le Dr. Kelth S. Champlin University of Minnesota, Minneapolis, Minnesota, USA. ‘This paper continues and significantly extends the results reported previously at Intelec 92 (3). lt demonstrates the thigh correlation of capacity and conductance on hundreds of ces in Telecommunication, U.P.S., Railroad signaling ‘and other usages. It confirms the premature capacity loss of Valve Regulated Lead Acid (VRLA) cells reported previously and provides information on failure modes viapost morta tear-down of some of the defective cells. Further it extends the correlation of conductance and capacity to tlooded lead acid cells and provides preliminary data of ‘capacity conductance correlation with flooded Nickel Cadmium (NiCd) batteries. It also introduces the results of techniques of noise suppression to allow on-line conductance measurements to be made on the batteries without interruption while the batteries continue in service. ‘Gonductance Technology Information on the theory and early background of conductance ‘esting o measure bator state-of heath was iecussod ina prev ‘Ou INTELEC publeation {3} and wil not be repeated here. Inthe past wo years conductance technology has been investigated ‘with moreating ites andes boon accoptedin many areas ote telecommunicaions industry as @ quick and rable technique for Bad 259 Assessment. $ Failures: & 259 oO — =98% Analysis of Strings 265 (2-15) 336 Celis. Figure 3 ity vs Conductan VRLA 1000 AH 336 Cells. for these tame stings with an overall accuracy of 88% (goodsbad) ‘and an accuracy of 88% in dtwotng fald capadty calls (<80%). ‘Teanamission Pient #2: VLA AGM, 1000 AH, Desion B. Manu: ‘achuneeA {In another transmission plant test of VRLA cols of 1000 AH size but ‘of a newer design, 192 calls arranged in eight parallel stings wore ‘valeted by conductance and discharge capacity tests. In tis ‘oction, 24 call data rom sting #3, peal ofthe other srngstastad \wilbo discussodin dota. Figure 4 shows capaciy stibuton data for sting #8. The capaciy distibuton shows significant capacity range withthe mejorty of cls faling well blow the 80% capacity faivre threshold (96 Mauss). Figure § shows tre coreiaion _ana)yis for this sting with an value of 0.81 showing excebent linear corelaton, similar to that reportad nthe previous pubheaton {}fordesign A. Aboxscore analysis shownin igure 6andhows ‘an overall suocesshil prediction of 83% (good + bad), with conduc tance successtuly predicting all the low capaciy cals with an accuracy of 100%. Figure 7 shows the compost analysis of ‘apacty distibuton for the entre plantas awhole and oary shows ‘he wide capacty distibuton of hese newer coll with many wal blow both their rated (120 mines} and 80 percent fare (05. minutes) valves. Overall conductancelcapacty comelaons for Capacity Test Outcome Conductance Test Outcome Bad Good Correct Assessment. Overall: Good 1 20 83% 24 Correct Assessment. Bad of Failures: 28 100% Total 24 Cells 19 String #8 Figure 6 Copacity Distribution. String #8. 24 Cells, 1000 AH. Theesold Proportion of Cells Tested 11> 40 sagan jortton of Calls Teat Capacity Distribution Transmission Plont #2 VRLA 1008 AN; Design B; 192 Cells. ™ Threshold 1199 30 sequen © 48 ae 128 168 208 Discharge Minutes To 2.88 YPC, Figure 7 Figure 4 Discharge Gopacity ve, Conductance ‘Viuas000 AN 24 Call, Sering #8 Oats, ope 2tt Amon Torte ity 2 ae es zo 3 * is ia 0 z 0 2 is » gs 8 Bea ‘0 20 mmm cence nan 68) anavtece Knee (Some) ten Figure 8 L igure ‘hose calle are shown in figure 8 and indicate excelent correlation F081. For thes calls, the Box score (igure 8) shows conduc. ‘ance overall predicton accuracy of 89% (good bad) while success- {uly predcing tow capacity calls (<80%) with an accuracy of 96%. ‘These results demonstrate again the effectveness of conductance in characterizing the capacity dstibuton among VALA coli in 8 (ven powerplant and in detacting premanure capacty fur Figure 10 shows the results of conductance measurements mace ‘on sting #2 dovign 8 ofthis same wansmistion plant. Cl #16 ‘moasured normal foat vlage and 2.11 vals open circuit but gave zero conductance reading during the conductance Wet. Upon ‘ppving the 269 amp load curent to this string, the exing vtugo immodiataly dropped below the low volinge cuff and the Aber discharge ‘hut down witin seconds, just as a roal system mightdo under an AC outage. Tear down analyst ofcol #16 revealedestasrophic corrosion ole negative rap. Manulacturors ‘alysis doteminedhigh antimony contentinthe buss lead, prosum- {ably die w the use of anincorrect buming stickin the manufacturing proceed Post Morta Exeminalion: Tranemisaion Plant £2 “Twenty four calls from sing #8 and 6 clis rom other sings were retumedto the manufacturer and etased for capacty anc conduc- ‘ance, Eight calls were then opened determine the conditono tho ‘lements and dlagnoce the cause of fare. Twenty ofthe 24 cals: from suing #8 which hed originally tostad rom 56% 992% capaci, ‘rect of lad at the wlophone office, recovered to 83% to 137% ‘capacty aher 3 dechargelrecharge cycles. Rechargoe wore par- formed on groups of 6 cole at @ constant voltage rate of 2:35 volts- ‘per-calfolowed by 19 amps (C/50) constant curt, unt vliages ablizedta: 10mV, Thectherfourcel, which hadorginaly teed, offload, at % 19 69% capaci el lslodaterScyces wih capaciios ‘anging from 0% to 70%. The 6 cols from the oer stings which had ‘tginally testa at 0% to 19% capacity cd nt recover, wih 9 cls fill snowing O% capaciy and the remaiing tree showing 8% 1 19% capacty ater three cycles. Fature modes were determined forthe 8 cols tom-down, Failures indlude; em 1, paral or complet negative sap corosion tlle; hem 2, positive gd corrosion, growth and grid frame tractures; im 2 ky Out lam 4 vory ow stack compression, [Al butone of he clls showing very low capacites had evidence of Ienemal ron contamination. The single high capaci cal (both of float and atthe manutactrer) showed no significant defects on tea: sown. Pir to final tests and prior to toar-down, conductance measure: ‘mans were made onal ces. Figure 11 shows percent capacity vs. ‘conductance for the cals as tated at the wlaphone office and indeatos a correlaton coefficient of F's.540. Also plotod is the capactylcondctance correlation plat forthe same cals as astod latter the cycing and boost charging by the manufacture. The ‘corelation coetfcient R'2a0.858 and regression nes are almost parabel, Despite the variety of fate modes the original conductance data deer detected hove cols which would tala of oad capaci test land would have faled had commercial power faled. After cycling ‘andboos charging, although many capectes improved (on average 2530%), the conductance stil corlated wel (R'= 858) w the Improved capactios and carly indicated those cals wich faled despia atompts at resuscitation, ‘Teanamigaton Plant #3: VRLA AGM, 1000 AH. Desion B: Meng: facta In anotver wlophone vansmission sits 1000 AH VRLA cals epprox: rmatelyfouryearsin age wrerecenty tasted. Both conductancaand several other stucos recently porformad, again demonstrate te ably of conductance testing in finding promature eapacty lost of Vat cols POST MORTA ANALYSIS - 225 AH CELLS JCELL#} CONDUCTANCE VALUES Siemens (Uhos) ccapacry ‘TEARDOWN OBSERVATION INFIELD INLAB@TEARDOWN INLAB_ @TEARDOWN t__ [1 29 oo 91% 2 [os 87 508 36% ‘Nop. buns lose; very sighty dry ls | 400 388 43 38% Pos. mid decharge: pj | Pos i coos a [ae 2st 22 o% Figure 20 12 VRLA 800 AH Cells Charge Capacity vs. On-Line/Off-Line Conductance M ounNvdaUONeD RAR o 1 2 3 4 5 ——@— OnLine Conductance (kMhos) —te— Off-Line Conductance (KMhos) Cell Numbers Figure 21 7 8 9 10 11°12 ‘Raliroad Sional Svetem: AGM 2004H, Deslon B, Manutacture A ‘As reportedin he previous nteec publoation {3}. Feld testing was ‘performed in ralroad signa site appicaions on VRLA 225 ampere hour calle. Typical ages for these ces wore tree 1o four years od. ‘Asample of four cls exhibiting iow, medium andhigh conductance, in addon Mo new calls, wore Sent to Midtronics laboratory for capacity testing, Figure 19 reveals the corelaton of conductance ‘end dscharge capeaty forthe sixcols.Throe subsoquentrecharye [and dhacharge tos wore performed with no appreciable improve- ‘mentin call condition measuedby either conductance or dscharge ‘capacity Post Morta Examination: Raitod Calls Figure 20 shows the summarized results rom measurements per. formedin the fal, ab and aha tor down. Post morta examination ‘wibte ferences in dry-out which accounted for the

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