Reliable batteries ensure that industrial systems will perform as expected and protect people, property and the wider environment. Proven technology such as nickel pocket plate batteries is economically and operationally effective. However, some operators are concerned that nickel batteries require a more complex charging process than lead acid batteries. Recent research and development activities in this area have focused on addressing this challenge.
Backup Batteries in the most Demanding Industrial Environments…
They must be reliable even in the harshest conditions. For this reason they can be installed in remote and inhospitable locations such as hydrocarbon exploration and production platforms, in unmanned service substations or in highly automated factories.
Backup batteries must be capable of generating power when necessary to safely carry out plant shutdown or operation of process control systems, ensure continuity of critical loads or reconfigure the electrical panel. Alternatively, a power bridge may also be required until backup generators are available, systems to protect data racks, generate backup power for fire alarms, emergency lighting and security systems.
All of the above must address the challenges of limited access, the need to comply with safety standards and procedures, and highly trained technicians.
How to Provide Power with Backup Batteries
The latest generation of nickel pocket plate batteries from battery factories such as Saft’s Uptimax , have evolved to offer the best charging capacity along with a high level of reliability . This charging capacity allows for easier management of battery chargers.
As batteries receive power, their voltage rises as their State of Charge (EoC) rises and they become saturated. The voltage window in conventional nickel batteries is relatively wide. In turn, this means that conventional nickel battery chargers must be adapted to first provide a rapid charge to bring the battery up to capacity and then a nominal ‘float’ charging voltage to maintain the charge.
To do this, in order to supply the two levels of charge for the batteries, additional drop diodes must be incorporated within the charger units. This allows fast charging and when it detects that the voltage increases, it switches to supply the float charge.
Reliability Benefit of Nickel Batteries
Aside from their improved charging capacity, newer pouch plate batteries have other advantages over lead-acid technology, particularly in terms of predictable performance, low maintenance requirements and low total cost of ownership (TCO).
Many operators have outdated facilities with lead-acid technology. Although lead-acid batteries are well-known and widely used, their maintenance and operating requirements, such as regular capacity testing, are relatively high. On the other hand, lead-acid technology can experience what we call sudden death.
It is a sudden and irreversible failure that is due to the internal structure of the battery finally losing its mechanical integrity because it is eroded over time due to electrochemical reactions. Nickel batteries do not experience sudden death; instead, they offer predictable performance over their lifespan.
These types of batteries also offer a much longer lifespan – meaning longer intervals between replacement cycles. In fact, customers frequently tell us that they have battery installations that are more than 20 years old. This feature is an advantage in remote and isolated installations , where the cost and logistical challenge of replacement can be high.
Two other factors that keep TCO in check are low maintenance and relatively lightweight compared to lead-acid technology. Batteries like the Uptimax do not require refilling with electrolyte. This means that site visits should be kept to a minimum and can be coordinated with other activities, avoiding the need to schedule a technician for batteries alone. In addition, being lighter than lead-acid, they are easier to handle and do not have the same requirements regarding transportation or handling.
