pti battery monitoring webinar #1
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
04/10/23 1
Worldwide excellence in battery monitoring
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
04/10/23 2
What is battery monitoring
Is a method to monitor rechargeable batteriesBy wikipedia
Battery Monitoring is,The tools to verify a batteries ability to supply design current under rated loadB
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
04/10/23 3
Batteries can fail in as little as 2 days making quarterlymaintenance totally inadequate in critical installations
Over 75% of UPS failures can be attributed to battery failure. (Including generator start batteries)
Any string of batteries is only as good as it’s weakest cell
“10 Year” batteries have a service life between 4 – 6 years(Typically changed out at three to four years)
“20 Year” batteries have a service life between 12 – 15 years(Typically changed out at 5 to 6 years)
Batteries near end-of-life have lost 20% of their original load capacityand 50% of their original runtime
…because investing in your UPS power protection equipment alone is not enough to guarantee that your UPS will be available when required.B
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Normal Conditions: 40 x 12 volt jars = 480V
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Single Battery Failure: 40 x 12 volt jars = 0V
40 Jar Cabinet Contains 240 Individual Cells
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Technology is the same as 100 years ago but spacerestraints are much tighter
Batteries are almost always designed down to a cost
Manufacturers have been forced to have their batteriesmade overseas to compete.
Quality is sacrificed for quantity, volume
Longer shipping distances, excessive handling, increases initial and ultimate failure rate and reliability
Bat
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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High or uneven temperatures
Inaccurate float charge voltage
Loose inter-cell links or connections
Loss of electrolyte due to drying out ordamaged case
Lack of maintenance, ageing
Design / published parameters never meet up with realistic expectations, 10yr only lasting 5yrs
Bat
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Batteries fail because they have:
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Plate separation
Plate cracking
Plate warping
Internal and external short-circuit
Grid corrosion
Sulfation of plates
Excessive gassing
Drying out
Thermal runaway• Most problems are not noticable visually
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These problems result in:
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Types of Batteries to Monitor
Lead Acid Lithium Ion
All VRLA Battery Types All Wet Cell Battery Types
UPS Applications Utility Applications
Telecom Applications Switchgear Applications
Remote Station Applications SubStation Applications
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Differences
In
Monitoring Solutions
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Cel
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Daily Cell or Jar/Block Ohmic Value (low energy)
Daily Cell or Jar/Block Voltage
Discharge Current
String Voltage
Discharge Time
String Currents
Pilot Temperature
Ambient Temperature
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Alb
er M
on
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Monthly Cell or Jar/Block Ohmic Value (low energy)
Daily Cell or Jar/Block Voltage
Discharge Current
String Voltage
Discharge Time
String Currents
Pilot Temperature
Ambient Temperature
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
04/10/23 12
Bte
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Bi-Monthly Cell or Jar/Block Ohmic Value (low energy)
Daily Cell or Jar/Block Voltage
Discharge Current
String Voltage
Discharge Time
String Currents
Pilot Temperature
Ambient Temperature
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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PM
Mo
nit
ors
…
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Quarterly Cell or Jar/Block Ohmic Value w/Cellcorder
Quarterly Cell or Jar/Block Voltage
NA……………..…Discharge Current
UPS ………………String Voltage
UPS ………………Discharge Time
NA ………………..String Currents
NA …………………Pilot Temperature
NA …………………Ambient Temperature
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Let us say your monitor checked your batteries on the 1st of September
The jar has fully failed on the 5th.4 days later
Some monitors only recommend testing every 14 days in this case leaving the customer exposed with a failed battery for 9 days
Some monitors even recommend testing only every 28 days in this caseleaving the customer exposed to battery failure for a whole 23 days!
Quarterly maintenance
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Complete failure took only two days
Cellwatch Alarms
Alarm investigatedBad bloc linked outBattery ordered
Battery replaced
Cellwatch Detects Failure
Alber & BTech do not
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Why not Battery Monitoring?
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Expensive compared to? • The Data Center being dropped? • UNPlanned outages?• Servers not restarting, failing• lost data? • lost revenue?• Lost faith in the system supporting the load
Don’t make the mistake of comparing the cost of a monitoring system with the cost of another battery string…
Even two strings….. Only 2 cells out of 480 can cause shutdown
“It is too expensive”
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Up to $50K46%
$50k to $250K28%
$251k to $1M18%
Over $1M8%
Hourly costs of unplanned downtime
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Still at risk of battery failure because you are not checking them daily.
Up to 5% of batteries fail during the warranty period, 2-3 years
Throwing away a high percentage of good batteries after 4 years
Throwing away dollars, odds are better, but you are still betting
Increased downtime, running on Generator, switching loads, increased opportunity for system failure
Environmental issues caused (disposal)
Expense of disposal
Who’s watching it when the installers go home?
“I change my batteries every four years”
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Servicing is better than no servicing but:
Still at risk of battery failure because you are not checking them
daily.
Four times a year is not enough in today’s critical uptime
environment
Handheld testing is not as repeatable as Cellwatch
Discharge tests, adverse effect on weak cells
What happens when the service engineers go home?
No real status on battery condition for 361 days out of 365.
“I have a battery service contract”
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Still at risk of battery failure because you are not checking them daily.
Does not give battery security unless it is used every day
Best case…no real battery status for 25% of the time (assuming a test every month).
Worst case…no real battery status for 92% of the time (assuming quarterly testing)
Not as repeatable as Cellwatch
Who is trending the data?
Much more labor intensive
Much more risk prone, safety issues (for the tester, the company and the battery)
Long downtime is essential each time it is used
“I have a handheld tester”
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Still at risk of battery failure because they won’t recommend daily
testing of ohmic values.
Cellwatch measures ohmic value daily and was specifically designed to do so
Cellwatch pioneered ohmic measurements in 1996 and still leads the way
Competitors “hit” their batteries with a much larger test load so have to recommend doing ohmic testing less often
Some competitors do not measure ohmic value at all
Cellwatch is the easiest, simplest and hence the quickest to install
Large conduit and cable-tray considerations with these older systems.
Competitors system constraints make a cluttered installation
“I always use another make of monitor”
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Courtesy - C&D Technology Inc
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In the late 1990s, Johnson Controls, (now C&D Batteries), produced a very comprehensive set of
literature on battery behavior. One of these is called:
“Impedance and Conductance Testing”
(Now referred to as Ohmic testing)
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Courtesy - C&D Technology Inc
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C &
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It also said that:“…actual values may vary +/-20% from value shown… The significance of
values measured lies not so much in the specific value but how the value changes from its original value over a period of time.”
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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This graph shows that with normal ageing these batteries have increased their ohmic value by 14% over 3 years (average)
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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If we take 2.4mOhms as the start point,Cell 1 reaches an increase of 25% on May 30thBecause Cellwatch measures daily Cell 1 is changed out immediately after the first alarm safeguarding the battery and the load!!
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Assuming the same delivery time to get a replacementcell, other monitoring systems could have left the customer exposed for much longer periods.
Quarterly maintenance only could mean up to 119 days exposure!
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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IEEE 1188 Manual System Cellwatch
Monthly System Float Voltage, Charger current, Temperature and ventilation and visual checks
Constantly
(Not ventilation although temp can indicate failed AC)
Not visual
Quarterly Monthly checks plus –
Cell / unit ohmic values, negative terminal temperature, interconnect resistance.
Voltage every hour,
ohmic once a day
Semi-annual
All monthly and quarterly plus –
Voltage of each cell / unit
Voltage every hour,
ohmic once a day
Yearly All the above plus cell to cell and interconnect resistance.
Performance Test
Voltage every hour,
ohmic once a day.
Any discharge
gives a graph of voltage performance under load
Manual testing vs. CellwatchOnly IEEE Cellwatch does not meet is the Visual Checks
IEE
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Cost justifications
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Based on 160 Jar System
Inspection & Test$1100 for 40 jars, $800 for each additional 40
jars$3,500 per visit x 4 = 14k annually
Discharge Test$5,600 – Conservative
Jar Replacement1% Annually
Battery replacement 4 years, cost 8.5K
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Cellwatch Installation; 1 Cabinet – 25K
PM Schedule changed to Annual -10,500 Over 12 years savings; $126,000 Due to 24 hour monitoring, increased battery usage to 7 years.Previous; 3 battery replacements, 12yrs 96KCurrent w/ Cellwatch; 2 battery replacements, 14yrs 64k Savings; 32k
Total Savings: Over 168K savings on this system
The above does not take in account the advantage of 24x7 monitoring. Also, any company with many strings Of batteries will see significant savings each year.ONLY replace batteries which need replacing.
CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Cellwatch systems are supporting critical loads in over 30 countriesaround the World
There are no customers, operating Cellwatch who have had a “dropped” load due to battery failure.
The reason?
Cellwatch is designed to monitor batteries for ohmic value DAILY
Cellwatch allows full visibility of the TOTAL battery install (including the generator)
High level of reliability is maintained by changing suspect cells well beforea failure occurs
Many Cellwatch systems pick up battery faults on install
Allows 24/7 monitoring
Gives REAL usable data of each cell or jar/bloc in the battery systemCel
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Daily monitoring of ohmic values
Advanced optical technology
CE & UL certified
Continuous monitoring 24/7
Scalable system
Fiber optic data highway
Easy to install, user friendly software
Measures: voltage, ohmic value, current and temperature
Actual on-battery indication of failed cell location
Full discharge recording
Remote monitoring facilities
Web browsing, Email alert, SMS
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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Eliminates costly downtime and disruption due to battery failure
Daily surveillance of ohmic values, 24 x 7 watchdog
Uses trending to highlight weakening cells prior to failure thereby
predicting battery failure
Optimizes battery assets by only replacing weak cells
Full cell/bloc history allows validation of battery warranty claims
Proactive versus reactive battery asset management
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CELLWATCH Everyday Battery MonitoringIf its not everyday its not battery monitoring
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If its not everyday its not battery monitoring
End presentation
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