Storage Batteries For Standby Application

Selection & Sizing

A Presentation by Exide Industries Limited

Selection Of Batteries For Generating Station And

Substation
Application :
-- Unit Battery
Substation Battery
PLCC
24/26v C & I Battery
UPS Battery
Battery for VHF set

August 13, 2015

Battery Is Considered To Be The HEART Of

The Power Plant
Battery provides the ultimate and final DC back-up for
operating emergency equipment which power the turbo
generators (viz. emergency oil pumps etc.)
DC power for operation of all switchgear, protection
relays, indicating lamps and facia
Power for emergency lighting within the generating
station building
Uninterrupted power for controlling C & I equipment and
associated ups systems
Power for vital communication equipment (plcc),
essential for re-synchronising the unit with the grid or
for reviving the grid in the case of a major grid failure
August 13, 2015

What If The Battery Fails In An Emergency

Unit Battery
The emergency oil pump will not operate which may
lead to seizure of the rotor bearings
Loss of hundreds of crore of rupees towards repairing
the rotor and generation revenue loss while the unit is
out of commission
Switchgear associated with generator may not trip
which could lead to generating transformer damage
Failure of instrumentation and control
Total darkness in the powerhouse
August 13, 2015

What If The Battery Fails In An Emergency

(contd.)

Substation

Switchgear and relays will not operate causing

extensive damage to transformers and power lines

PLCC
Extremely difficult to resynchronize the unit with the grid
Major setback in the process of reviving the grid in the
event of a regional grid failure
If the battery fails while the unit is in operation, it may
become essential to shutdown

August 13, 2015

The Single Most Important Feature Of Storage Batteries For

Power Sector and Other Critical Standby Application Is

Reliability
Reliable standby power source
Deliver power as and when called for
Full capacity at any point of time in service life
Predictability

August 13, 2015

STORAGE BATTERY
WHEN ?
EITHER
SUDDEN DISRUPTION OF MAINS POWER TAKES PLACE
OR
CONVENIENT AVAILABILITY OF MAINS POWER IS NOT THERE
THIS CLEARLY DEFINES TWO REGIMES OF APPLICATION

STANDBY APPLICATION

UPS, INVERTERS, TELEPHONE

EXCHANGES, POWER STATIONS,
SWITCHING

CYCLIC APPLICATION

CELL PHONES, TOYS, FORK

LIFTS, ELECTRIC VEHICLES,
SOLAR PHOTOVOLTAICS

SELECTION HEURISTICS

KNOWLEDGE OF
ATTRIBUTES OF
COMPETING
TECHNOLOGIES

KNOWLEDGE OF
ATTRIBUTES OF
DESIGN OPTIONS

KNOWLEDGE OF
APPLICATION
REQUIREMENTS

SELECTION OF RIGHT
TECHNOLOGY

SELECTION OF RIGHT
DESIGN

General Battery Technologies

Most Popular Electrochemical Couples used worldwide in
Industrial Application
LEAD ACID
NICKEL CADMIUM

BASIC ELECTROCHEMISTRY
LEAD ACID
CHARGED

DISCHARGED

PbO2 + Pb + 2H2SO4
POS

PbSO4 + PbSO4 + 2H2O

NEG.

POS

NEG.

ELECTROLYTE TAKES ACTIVE PART IN REACTION SPECIFIC GRAVITY

CHANGES WITH STATE OF CHARGE EASY MONITORING AND INDICATION
OF STATE OF CHARGE (SOC)

NICKEL CADMIUM
DISCHARGED

CHARGED

2NiOOH + 2H2O + Cd
NEG.

POS

2Ni(OH)2 + Cd(OH)2
NEG.

POS

ELECTROLYTE DOES NOT TAKE ACTIVE PART IN REACTION SPECIFIC

GRAVITY DOES NOT CHANGE WITH STATE OF CHARGE NO DIRECT &
EASY METHOD OF MEASURING STATE OF CHARGE

Advantage Lead Acid

More than 90% of applications world-wide use
Lead-acid
Reasons:

LOW COST

APPLICATION VERSATILITY

ABUNDANT RAW MATERIAL

WELL DEVELOPED SERVICING RECYCLING

INFRASTRUCTURE

Nickel Cadmium

Advantage
1. Excellent cycling capability
2. Excellent Recovery from Deep Discharge
3. Best High Rate Discharge characteristics
Limitations
1. Cell voltage 1.2V number of cells much higher for a
given system voltage as compared to lead-acid.
2. No means of assessing state of charge.
3. Does not retain full charge on float condition
requires frequent boost charge.
4. Charge acceptance at high temperature is poor.
5. Suffers from Memory Effect.
Reliability in critical float applications is not assured.

The Lead-Acid Technology

Technology Wise Categorisation
Industrial Lead Acid Battery

FLOODED

FLAT

TUBULAR

VRLA

PLANTE

LEAD ACID BATTERY

PLATES ARE
CONSTITUTED
OF

AN OVERVIEW

ACTIVE MATERIAL

SUPPORT STRUCTURE

TAKES ACTIVE PART IN

REACTION TO STORE &
SUPPLY ENERGY

ACTIVE
MATERIAL

SUPPORT
STRUCTURE
2

ENABLES ELECTRONIC
CONDUCTION
PROVIDES MECHANICAL
SUPPORT TO ACTIVE
MATERIAL

FLAT PLATE

MORPHOLOGY

WIRE-MESH LIKE SUPPORT

STRUCTURE GRID CAST OF LEAD
ALLOY, ANTIMONY OR CALCIUM

ACTIVE MATERIAL
PASTED ON GRID EXTERNALLY

A CHEMICAL BONDING HOLDS THE ACTIVE

MATERIAL IN PLACE THROUGHOUT THE
SERVICE LIFE

FLAT POSITIVE PLATE

ADVANTAGES
MINIMUM LEAD

MOST ECONOMIC & HIGHEST

ENERGY DENSITY

LARGE ACTIVE
SURFACE AREA

EXCELLENT HIGH RATE

DISCHARGE PERFORMANCE
AND CHARGE ACCEPTANCE

LIMITATIONS
ACTIVE MATERIAL
SHEDDING

LIMITED CYCLING
CAPABILITY

EASY ACCESS OF
ACID TO LEAD GRID

EASY CORROSION LOW

LIFE EXPECTANCY

MOST SUITABLE FOR HIGH CURRENT, SHORT DURATION

APPLICATION viz. SLI, SHALLOW DUTY INVERTER ETC.

TUBULAR POSITIVE PLATE

MORPHOLOGY

GAUNTLET + BOTTOM BAR + LEAD TOP BAR

RETAINS THE ACTIVE MATERIAL

LEAD TOP BAR

ACTIVE
MATERIAL

SPINE

GAUNTLET

PLASTIC BOTTOM BAR

TUBULAR POSITIVE PLATE

WHY ?

ADVANTAGES
NO ACTIVE MATERIAL
SHEDDING
SPINE DEEPLY
EMBEDDED IN ACTIVE
MATERIAL LOW SPINE
CORROSION

LOOSE PACKING OF
ACTIVE MATERIAL
POSSIBLE

BEST SUITED FOR

CYCLING 1500 CYCLES
@ 80% DOD
EXTREME TEMPERATURE
OPERATION
RESISTANT TO OVERCHARGE
RECOVERY FROM DEEP
DISCHARGE
PSOC OPERATION

EXTENDED SERVICE LIFE. IT IS DESIGNED FOR DEEP CYCLING

TUBULAR POSITIVE PLATE

WHY NOT ?

LIMITATIONS

MODEST HIGH RATE DISCHARGE

PERFORMANCE.

REQUIRES PERIODIC EQUALIZING AND/OR

BOOST CHARGING

REQUIRES PERIODIC TOPPING UP

ANTIMONY POISONING LEADS TO SLOWLY

DECLINING VOLTAGE PROFILE AND
INCREASING WATER LOSS AS THE BATTERY
AGES.

Exide OPzS

The Next Generation Tubular Battery

Exide OPzS

Exide OPzS comes with Heavy Duty DIN standard Spine

HIGH PRESSURE SPINE CASTING IN HADI MACHINES

GRAVITY CAST (1 Bar)

CAST IN LOW PRESSURE (10 Bar)

CAST IN HADI (100 Bar)

Exide has introduced a unique hybrid concept in this country. Low

antimonial positive spine alloy with lead-calcium negative. This toget
with the benefit of Hadi casting leads to:
Extremely Corrosion Resistant Positive
Alloy
Drastically reduced water loss

Exide OPzS
Comparative Water Loss study data:
Positive
Spine Alloy

Negative
Grid Alloy

Rate of water loss on float # per

Ah/Cell/21 days at 50oC, 2.4 V/cell

Till late 80

9% Sb

5% Sb

1.10 gms.

Post 90

5% Sb

2.5% Sb

0.55 gms

Exide OPzS

2.5% Sb

0.1% Ca
0.3% Sn

0.18 gms

# Test Specification as per RDSO low maintenance battery requirements

In the absolute worst case too, cells do not require topping up in 1 y

Exide OPzS
The Exide OPzS range of Tubular Cells
Now come in transparent, tough StyreneAcrylonitrile (SAN) boxes clear as glass.
Easy to monitor State-ofHealth !!
Additional Features

Ceramic Dome Filter

Plastic Encapsulated
Strap for corrosion
resistance

Insulated Connectors

EXIDE PLANTE

PLANTE

MORPHOLOGY

CAST OF 99.99%
PURE LEAD

LAMELLAR GRID

STRUCTURE
ENHANCED
ACTIVE SURFACE
AREA

INTEGRAL GRID

ACTIVE MATERIAL

PLANTE

HANGING PLATE DESIGN

POSITIVE PLATE HANGING FROM
CONTAINER SHOULDER

POSITIVE PLATE
HANGING FROM
CONTAINER SHOULDER
TO PROVIDE SPACE FOR
CREEP GROWTH
INEVITABLE TO PURE
LEAD POSITIVE

GAP BETWEEN POSITIVE PLATE

BOTTOM & MUD RIB FOR CREEP
GROWTH ALLOWANCE

Integral Grid-Active Material

1. In case of loss of active material due to

shedding, next layer of pure lead is converted
to lead-dioxide thereby ensuring no loss of
capacity feature of continuous regeneration of
active material.
2. Across its life time Plante cells therefore
perform at full capacity there is no aging
unlike all other lead-acid products.
3. No aging factor required for capacity calculation

FLOAT CURRENT VS SERVICE LIFE

Plante
10 A

FLOAT CURRENT

Low Sb Tubular
SbCdVRLA
NormalTubular

10yrs

SERVICE LIFE

20 Yrs.

PLANTE

NO LOSS IN CAPACITY

CONTINUOUS REGENERATION OF ACTIVE MATERIAL

TOTAL LEAD-DI-OXIDE CONTENT FAIRLY
CONSTANT THROUGHOUT THE LIFE
SPAN INDICATING A CONSTANT CAPACITY
OUTPUT

CAPACITY DEGRADATION OVER LIFE

AGEING FACTOR

TUBULAR

20%

1.25

VRLA

20%

1.25

Ni-Cd

20%

1.25

PLANTE

ZERO

1.00

PLANTE

FAST RECHARGE

HIGH SURFACE AREA

HIGH CHARGING RATES POSSIBLE.

CHARGING AT 0.25 C10 AMPS UPTO
2.4 VOLTS PER CELL WITHOUT
PROBLEM

NO ANTIMONY POISONING

HIGH FLOAT POTENTIAL POSSIBLE.

PLANTE

LONG LIFE

VERY THICK POSITIVE ENOUGH CUSHION AGAINST

CORROSSION

LOW SUSCEPTIBILITY TO OVERCHARGE

DUE TO
VERY LOW EQUILIBRIUM FLOAT CURRENT OF
THE ORDER OF 1 mA/AH UNDER NORMAL FLOAT
CONDITION

LOW FLOAT CURRENT AND HIGH PURITY OF LEAD

LOWERS THE CORROSSION RATE

LIFE EXPECTANCY OF 18 TO 20 YEARS PLUS.

PLANTE

EASY MONITORING

TRANSPARENT SAN (STYRENE ACRYLONITRILE)

CONTAINER EASY VISUAL MONITORING OF CELL INSIDE

ANY ODD BEHAVIOUR CAN BE MONITORED AND

CORRECTED MUCH BEFORE IT SHOWS UP AS A
FAILURE MODE

EASY CLEANING OF CELLS FROM UNAVODABLE

SLUDGE DEPOSITION TO AVOID SHORT CIRCUIT
AND RELATED TROUBLES

RELIABILITY - REITERATED

WHAT IS VRLA ?

SEALED
CAN BE KEPT
IN ANY ORIENTATION.
NO TOPPING-UP REQUIRED
EVER MAINTENANCE-FREE.
A ZERO EMISSION PRODUCT.
BATTERY COMES CHARGED.
COMPACT.

Advantage VRLA

1. No topping up ever
2. No emission of fumes
3. Supplied factory charged
4. Excellent high rate discharge performance
5. Excellent charge acceptance
6. Excellent deep cycle life
7. Low Self-discharge
8. Designed to suit float and moderate cyclic duty
9. Compact low foot print
10.Long Life

The Oxygen Recombination Cycle

FLOODED SYSTEM
e-

Pb

PbO2

H+

H+

O2
H+

Pb

Charger

H2
PbO2

Charger

O2

VRLA
SYSTEM

e-

H+

2Pb + O2= 2PbO

PbO + H2SO4
= PbSO4 + H2O
PbSO4 + 2e- + 2H+

O2
ELECTROLYTE - H2SO4

= Pb + H2SO4

ABSORPTIVE SEPERATOR - ELECTROLYTE

MECHANISM DURING CHARGING

At +ve Electrode

At -ve Electrode

2Pb + O2= 2PbO

(Exothermic Reaction)
PbO + H2SO4 = PbSO4 + H2O
(Exothermic Reaction)
PbSO4 + 2e- + 2H+ = Pb + H2SO4 (Electrochemical Reaction)
RECOMBINATION MECHANISM OF VRLA CELLS WITH MICRO GLASS
SEPERATORS IN COMPARISON WITH FLOODED CELLS

H2O=1/2O2 + 2H+ +2e-

August 13, 2015

Venting Arrangement Of A VRLA Battery

August 13, 2015

VRLA Limitations

1. No means of state-of-charge assessment

2. Vulnerable to prolonged operation at high temperature

3. Sensitive to both under and over charge
4. Recovery from over discharged condition is difficult

5. Can have a catastrophic failure in case of charger

malfunction and/or abnormally high temperature
operation a failure mode known as thermal runawa

SIZING FACTORS

PARAMETERS

LOAD CURRENT
LOAD DURATION
PRIMARY

NOMINAL SYSTEM VOLTAGE

MINIMUM SYSTEM VOLTAGE

MINIMUM OPERATING TEMPERATURE

DESIGN MARGIN
AGING FACTOR

FACTORS SPECIFIC TO APPLICATION

SECONDARY

Selection Parameters
SELECTION OF THE RIGHT TYPE OF TECHNOLOGY AND
DESIGN PRECEDES THE SIZING EXERCISE

DEPTH OF DISCHARGE
FREQUENCY OF DISCHARGE
PARAMETERS
TO BE
CONSIDERED
FOR SELECTION

APPLICATION CRITICALITY
CHARGING CONSTRAINT
MAINTENANCE CONSTRAINT
OPERATING CLIMATIC CONDITIONS
SPACE AVAILABLITY

Selection Summary

APPLICATION
ATTRIBUTE

DEPTH OF
DISCHARGE
FREQUENCY OF
DISCHARGE
CRITICALITY OF
APPLICATION
CHARGER
CONSTRAINT ON
VOLTAGE
MAINTENACE
CONSTRAINT
OPERATING TEMP.

HIGH

MODERATE

LOW

TUBULAR

TUBULAR /
VRLA

VRLA /
PLANTE

TUBULAR

TUBULAR /
PLANTE

PLANTE /
VRLA

PLANTE

PLANTE /
TUBULAR

TUBULAR /
VRLA

TUBULAR

VRLA

PLANTE /
TUBULAR

PLANTE /
TUBULAR

TUBULAR /
PLANTE

PLANTE / VRLA

VRLA

BATTERY SIZING

Sizing Parameters
DUTY CYCLE LOAD CURRENT
AND DURATION PATTERN

APPLICATION
PARAMETERS

OPERATING DC BUS VOLTAGE

WINDOW MAXIMUM & MINIMUM
DC BUS VOLTAGES
MINIMUM AMBIENT TEMPERATURE
DESIGN MARGIN
CHARGING VOLTAGE REQUIREMENT

BATTERY
PARAMETERS

DISCHARGE CHARACTERISTICS
FACTOR FOR AGING PHENOMENON
FACTOR FOR STATE-OF-CHARGE IF
REQUIRED

SIZING OF STORAGE BATTERY FOR STANDBY FLOAT APPLICATION

STEP 1

NUMBER OF CELLS =

CALCULATION OF NUMBER OF CELLS

MAXIMUM DC BUS VOLTAGE

RECOMMENDED FLOAT VOLTAGE OF EACH CELL

NO OF CELLS FOR PLANTE =

NO OF CELLS FOR NICD =

NO OF CELLS FOR OPzS =

242
2.25
242

= 108

= 173

1.40
242
2.23

= 108
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SIZING OF STORAGE BATTERY FOR STANDBY FLOAT APPLICATION

STEP 2

END CELL VOLTAGE =

WORKING OUT END CELL VOLTAGE

MINIMUM DC BUS VOLTAGE

NUMBER OF CELLS (FOUND FROM STEP NO 1)

END CELL VOLTAGE FOR PLANTE =

END CELL VOLTAGE FOR NICD =

192
108
192

= 1.78

= 1.11

173
END CELL VOLTAGE FOR OPzS =

192
108

= 1.78
45

SIZING OF STORAGE BATTERY FOR STANDBY FLOAT APPLICATION

STEP 3

CALCULATION OF AH CAPACITY

AH CAPACITY = K FACTOR x LOAD CURRENT

STEP 4

APPLY DESIGN MARGIN

DESIGN MARGIN IS BASICALLY THE FACTORY OF SAFETY AND

INSURANCE AGIANT ANY POSSIBLE INCREASE IN LOAD

46

SIZING OF STORAGE BATTERY FOR STANDBY FLOAT APPLICATION

STEP 5

APPLY TEMPERATURE CORRECTION FACTOR

AT LOWER TEMPERATURE, CAPACITY OF ANY STORAGE BATTERY

DECREASES . SINCE THE SYSTEM MUST WORK PROPERLY AT LOWEST
AMBIENT TEMERATURE ALSO, RAW CAPACITY NEEDS TO BE
ADJUSTED BY APPLYING SUITABLE TEMPERATURE CORRECTION

STEP 6

APPLY AGING MARGIN

CAPACITY OF ANY STORAGE BATTERY (EXCEPT PLANTE)DECREASES WITH

AGE. SINCE THE SYSTEM REQUIREMENT DOES NOT CHANGE AND A BATTERY
SHOULD BE REPLACED WHEN IT REACHES 80% VALUE, 25% AGING MARGIN IS
CONSIDERED FOR TUBULAR, VRLA AND NICD BATTERIES.
47

SIZING OF STORAGE BATTERY FOR STANDBY FLOAT APPLICATION

STEP 5

APPLY FLOAT CHARGE CORRECTION FACTOR

THIS FACTOR IS APPLICABLE FOR NICD BATTEREIS ONLY AND NOT

FOR ANY LEAD ACID BATTERY.
NICD BATTERY,WHEN CONNECTED ON FLOAT FOR A PROLONGED
TIME,LOSES ITS CAPACITY AND THEREFORE IT MAY NOT DELIVER
FULL CAPACITY DURING EMERGENCY DISCHARGES. IN ORDER TO
ADDRESS THIS DEFICIENCY FLOAT CHARGE CORRECTION FACTOR IS
APPLIED TO ARRIVE AT REQUIRED CAPACITY.

48

STEP 3 : CALCULATION OF FINAL CAPACITY

BASIC RATED CAPACITY OF THE CELL
C=IXF
FACTOR FOR AGING,
A

DESIGN MARGIN, D

FACTOR FOR
TEMPERATURE
CORRECTION, KT

STATE-OF-CHARGE /
FLOAT CHARGE
CORRECTION
FACTOR, Z *

FINAL CALCULATED CAPACITY

CF = C X A X D X K T X Z
*

REQUIRED ONLY FOR Ni-Cd BATTERY

SOFTWARE ALGORITHM

ENVIRONMENT
PARAMETERS

SYSTEM
PARAMETERS

LOAD
PARAMETERS

BATTERY TYPE
SELECTED

USERS
CONFIRMATION

BATTERY SIZING
TOOLKIT
NO. OF
CELL

SELECTED
MODEL

SIZING CALCULATION

PRODUCT CATALOGUE

GUARANTEED TECH PARTUCULARS

O & M MANUAL

STANDARD LAYOUT

THANK YOU

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