ESAConsulting Engineers, PA
Florida Board of Professional Engineers - CEP 00184
STATIONARY BATTERY VISUAL INSPECTION AND PROBLEM IDENTIFICATION SHORTCOURSE
(ESA-0301)
0.4 CEUs Awarded
OUTLINE
| TIME |
SUBJECT |
| 8:30 AM - 8:45 AM |
Introduction, Substation Failure Video |
| 8:45 AM - 9:15 AM |
Stationary Battery Applications |
| 9:15 AM - 10:15 AM |
Stationary Cell Ratings, Chemistry, Cell Types, Plate Types, and Vented vs. Valve Regulated |
| 10:15 AM - 1:00 PM |
Visual Inspections, Problem Identification and Corrective Actions |
OBJECTIVE, SKILLS & TARGET POPULATION
OBJECTIVE
The objective of the Stationary Battery Visual Inspection and Problem Identification Shortcourse, is to provide the participants with specific knowledge of how to perform a detailed visual inspection of a stationary battery installation and how to identify potential problems, often before they may be detected by measurements and tests. The participant will also be provided with the knowledge on the corrective actions to be taken once a specific problem has been identified. The participant will be provided with the knowledge to perform a detailed visual inspection of the battery rack or cabinet and will discuss inspection of a spill containment system. As part of the shortcourse, the participants will learn the basic components of a stationary battery cell and the function of each. The basis for ratings applied to stationary batteries is discussed, as well as, cell chemistry for lead-acid and nickel-cadmium cells. The various plate types used with each cell type (e.g., for lead-acid, Planté, Fauré, tubular) will be discussed, as well as, the alloys used for lead-acid plates. The differences between vented and valve regulated cells are described. The shortcourse exposes the participants to a variety of battery installations and problems through the use of photographs. For those participants that are more experienced with stationary batteries, the shortcourse provides an opportunity for gaining a greater depth of knowledge of stationary battery visual inspection and problem identification.
SKILLS
After completing the shortcourse, the participant will be able to recognize the types of stationary batteries available and identify applications they are commonly used in. The participant will recognize that there are various plate designs available depending upon the battery type used and the reasons why one type may be preferred over another type for a specific application. The participant will also recognize that lead-acid cell plates can be manufactured using one of several lead-alloys, each of which has advantages-disadvantages. The participant will be familiar with the reactions that occur when the battery is discharged/charged. The participant will be able to recognize the items that must be considered when performing a visual inspection of a battery. The participant will be able to identify the visual inspections required for a battery and their frequency. He/she should be able to identify common battery problems and understand why they occur. The participant will be able to describe the corrective actions to be taken once a problem is noted and the urgency of the corrective action (e.g., immediate replacement or replacement within 4 to 6 months).TARGET POPULATION
Maintenance, system or design engineers, operations personnel, technicians and electricians wishing to learn about stationary batteries and the visual inspections that can be used to diagnose problems or determine the state-of-health of the stationary battery. The course provides information for both the novice and experienced battery person alike.SHORTCOURSE DESCRIPTION
THE STATIONARY BATTERY VISUAL INSPECTION AND PROBLEM IDENTIFICATION SHORTCOURSE
The shortcourse was developed as a subset of the two-day Stationary Battery Seminar that has been regularly presented for more than 17 years to thousands of engineers and battery professionals of all experience levels. More than 600 companies including battery manufacturers, utilities, telecommunications companies, banks, hospitals, securities companies, industrial companies, government agencies, armed forces, instrument companies, national laboratories, UPS manufacturers, battery maintenance companies, etc., have sent their personnel to the Seminar. The shortcourse is updated on a regular basis to reflect not only typical problems that may be observed during visual inspections but to include problems that have been identified (e.g., through operating experience and feedback) as been observed currently on installed battery systems. Examples of this would include post leaks being experienced by one manufacturer’s cells due to procedure changes made by the manufacturer in its formation process. Another example is a particular post seal design that is prone to experience nodular or crevice corrosion after 5-7 years of operation.
Although stationary battery systems were once limited to the telecommunications companies, electric utility companies and heavy industrial facilities, they have become commonplace in commercial buildings, health care facilities and financial institutions, just to name a few. In addition, battery manufacturers have introduced so called “sealed” and “maintenance-free” batteries in the marketplace. As industry has found out, these batteries are neither, and in fact, require more maintenance checks than do equivalent flooded batteries. However, there are no courses on stationary batteries readily available at schools or colleges, nor are there any modern textbooks that deal with the topic.
Maintenance, system or design engineers, operations personnel, technicians and electricians involved in the design, installation, maintenance and testing of stationary battery systems whether installed as part of an emergency power system, a stand-alone system or an uninterruptible power supply (UPS) system, require training in the proper methods to visually examine stationary battery cells, identify problems and determine the proper corrective action to take once a problem is identified.
STATIONARY BATTERY APPLICATIONS
This portion of the shortcourse is a brief review of the many applications for stationary batteries in the “information age.” There is also a discussion of the type of loads that these batteries supply as part of an emergency, stand-by or uninterruptible power system.
CELL RATINGS, PLATE TYPES, ALLOYS AND CHEMISTRY
This portion of the shortcourse discusses the basis for rating stationary cells (or batteries) in North America. There is also a discussion of the chemistry of electrochemical cells (including the lead-acid and nickel-cadmium types), including the overall charge-discharge reaction, as well as, the reactions that occur at each of the cell electrodes. The various plate designs that are available on the market are discussed, as well as, the alloys used in the manufacture of lead-acid plates. The discussion will touch on the pros and cons of the plate designs and alloys (e.g., cycle life, suitability for use in higher ambient temperatures, resistance to corrosion).
VENTED VS. VALVE REGULATED
This portion of the shortcourse discusses the similarity and differences between vented and valve regulated lead-acid cells using a comparison of each cell type’s gassing reactions as a starting point. It explains why the terms “maintenance-free” and “sealed,” which are still commonly used to describe valve regulated lead-acid cells are misnomers. There is also a discussion of the absorbed glass mat and gelled-electrolyte designs. This discussion is meant to ensure that the participants understand that there are two design types of valve regulated lead-acid cells and to dispel the common misconception that all valve regulated cells are “gel-cells.” Photographs, including cell and component cutaways are used to reinforce understanding of the concepts presented.
VISUAL INSPECTION
This portion of the shortcourse discusses each of the basic components of a stationary battery cell and their functions. This portion of the shortcourse is based upon guidance provided by battery manufacturers, IEEE® Standards 450TM, 1106TM and 1188TM, and the course developer’s experience. Safety procedures and protective equipment are included in the discussion for information. There is also a discussion on identification of cells, identification of the date of manufacture and why it is important to know the date code of a battery prior to inspecting it. It discusses the visual inspections that can be made on each of these components and what should be observed for a “healthy” cell. For example, the color of fully charged positive and negative plates in a lead-acid cell. This portion of the shortcourse also discusses the visual inspections that can be made on a battery rack or cabinet, including seismic equipment, if the rack or cabinet is so equipped. There is also a short discussion on visual inspection of spill containment systems used in conjunction with stationary batteries.
PROBLEM IDENTIFICATION
Numerous photographs are used to illustrate the various problems that may be identified by a detailed visual inspection of a battery. There is also a discussion of a number of conditions that are often mistaken for problems, but are not (e.g., treeing and retainer break-up). The purpose of this module is to provide the participants with the knowledge necessary to: identify problems early; understand why the problem has occurred and identify its root cause; and recognize conditions present in a battery that are “cosmetic” in nature.
CORRECTIVE ACTIONS
The corrective actions in the shortcourse are based upon guidance provided by battery manufacturers, IEEE® Standards 450TM, 1106TM and 1188TM and the course developer’s experience. The module describes the corrective actions to be taken as a result of the analysis of maintenance inspection data. The urgency of implementing the required corrective actions is discussed. This portion of the shortcourse will provide the participants with the knowledge necessary to: understand what corrective actions are and how they should be implemented. It provides the participant with the knowledge of the time frame in which the corrective actions need to be performed and in some instances, the requirements for additional monitoring of the battery’s condition until the corrective actions are implemented.
ESA Consulting Engineers, PA
PO Box 9251 Jupiter, Florida