Professional Documents
Culture Documents
FMDS0528 DC Battery Systems
FMDS0528 DC Battery Systems
DC BATTERY SYSTEMS
Table of Contents
Page
©2021 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced,
stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.
5-28 DC Battery Systems
Page 2 FM Global Property Loss Prevention Data Sheets
List of Figures
Fig. 1. Sulfation growth at different stages observed through visual inspection .......................................... 12
Fig. 2. Normal and excessive sediment observed at visual inspection ....................................................... 12
Fig. 3. Severely low electrolyte observed at visual inspection ..................................................................... 13
Fig. 4. An example of VRLA battery with design life of 5 years in a controlled temperature environment . 17
List of Tables
Table 1. Inspection, Testing, and Maintenance ............................................................................................. 7
Table 1a. Acceptance Criteria for Battery Tests ............................................................................................. 8
Table 2. Visual Indications and Likely Causes for Flooded Lead Acid Batteries ......................................... 13
Table 3. Tests and Failure Modes for Lead Acid and Nickel Cadmium Batteries ........................................ 16
Table 4. Example of a Battery Capacity Rating Table Provided by a Manufacturer .................................... 18
Table 5. FM Global Battery-Related Losses by Peril, 2000-2019 ................................................................ 20
1.0 SCOPE
This document provides design, operation, inspection, testing, and maintenance guidance for DC battery
systems used for standby operations in stationary applications, including, but not limited to, power-generating
stations, substations, telecommunications, data centers, switchgear protection systems, process control
systems, emergency power supplies, and uninterruptable power supplies. In these applications, the operation
of DC systems results in the batteries operating most of the time on a float charge with infrequent discharge
(i.e., float service).
For lithium-ion batteries used for standby operations, refer to FM Global Property Loss Prevention Data Sheet
5-33, Electrical Energy Storage Systems, for loss prevention recommendations related to fire hazards.
This data sheet does not cover energy storage batteries, diesel engine startup batteries, batteries in mobile
equipment (such as lift trucks and cranes), or the storage of batteries.
1.1 Hazards
A stationary standby battery is a critical component of an electrical protection system and/or emergency power
system used to protect connected equipment and systems from electrical faults or system disturbances that
could result in equipment damage, arcing fault, fire, or unsafe shutdown of a critical process.
1.2 Changes
April 2021. This is the first publication of this document.
2.2.5 When flooded batteries are located on upper floors, seal all floor penetrations within 10 ft (3 m) of the
battery rack.
2.3.3.1 General
2.3.3.1.1 Design the battery size (capacity and duty cycle) with consideration of the following criteria, at a
minimum (refer to IEEE 485 and IEEE 1115 for more sizing guidance):
• DC load profile, including number of loads, sequence in which the loads draw current, and current and
duration of each load
• Minimum operating voltage for DC loads when the battery reaches its end of discharge (i.e., 80% of
capacity)
• Lowest ambient temperature expected at battery
2.5.1 General
2.5.1.1 Operate the battery and its support systems in accordance with approved operating instructions and
within prescribed battery thermal and electrical limits (i.e., float/equalizing voltage limit).
2.5.2.3.1 Where an online battery monitoring system is installed, perform monthly visual inspections and
test the parameters listed in Table 1 that are not specifically monitored by an online system and reviewed
by site personnel. Perform capacity tests at the frequency specified in Section 2.5.2.4.
2.5.2.4 Perform a capacity test (also called “performance test” or “discharge test”) every five years for flooded
lead acid, flooded nickel cadmium batteries, and every two years for sealed lead acid (VRLA) batteries. When
deterioration in capacity is noticed, increase the frequency of testing to once every year.
Excessive capacity deterioration is indicated when the capacity drops below 90% of rated value for lead
acid batteries, and when the capacity drops more than an average 1.5% per year of rated capacity from its
capacity on the previous testing for nickel cadmium batteries. During capacity testing, perform the following
activities:
A. If the battery under test is the only one installed, connect a spare battery bank to the system to allow
the battery bank to be isolated for testing without jeopardizing the electrical system in the event a fault
incident occurs during the capacity test. Alternatively, perform the test during the planned outage.
B. Perform infrared scanning on battery system components whenever applicable to detect any
overheating-related deficiency.
Batteries are designed with a certain amount of cycling life (>100 cycles). By following the recommended
testing frequency in this data sheet, a battery will be capacity tested up to about 10 times in its life. Therefore,
the recommended capacity testing will have a negligible impact on battery life.
2.5.2.5 For lead acid type, replace the battery system when its measured capacity approaches 80% of its
rated capacity. For nickel cadmium batteries, replace at 70%.
When lead acid and nickel cadmium batteries are replaced with lithium-ion batteries, consult with battery
and equipment OEM to ensure matching performance, such as voltage between the existing charger and the
level required by the li-ion battery systems, and their battery management systems.
2.6 Training
2.6.1 Develop emergency operating procedures for the following scenarios:
• Loss of DC power
• DC bus undervoltage alarm
• Excessive H2 alarm for lead acid and nickel cadmium battery systems
• Emergency DC system in service alarm (i.e., loss of primary AC power)
• Charger output failure alarm
• Battery condition monitoring system alarm
2.6.2 For installations with lithium-ion batteries, provide the operators and key site personnel who interact
with the batteries with training and awareness of lithium-ion battery thermal runaway, fire, and explosion
hazards. Develop an emergency response plan for fire and thermal runaway incidents.
2.6.3 Develop a standard operating procedure for the following activity, at a minimum:
• Operating when the N+1 redundancy in the DC battery system is lost due to a planned outage
2.6.4 Develop, maintain, and train operators on the standard and emergency operating procedures. See
Data Sheet 10-8, Operators, for guidance on developing operator programs.
2.7.2 Sparing
Sparing can be a mitigation strategy to reduce the downtime caused by a battery breakdown, depending
on the type, compatibility, availability, fitness for the intended service, and viability of the sparing. For general
sparing guidance, see Data Sheet 9-0, Asset Integrity.
3.3.1 General
Normal wear-out or aging mechanisms are part of normal operation. The aging of batteries can be split into
two categories: calendar aging and cycling aging. The aging mechanisms in each category are fundamentally
different. The overall aging of a battery in an application will be a combination of the two categories and
will depend on duty cycle and other operating conditions. Aging eventually involves the reduction of available
capacity. For lead acid batteries, aging proceeds linearly to 80% of rated capacity and then accelerates.
Thus, an 80% value is often called the “knee point” of its aging curve. Operating beyond the knee point
significantly increases the risk of a battery failing to power critical load during an emergency. For nickel
cadmium battery, the knee point is typically 70% of rated capacity. Lithium-ion batteries typically have
60%-70% of rated capacity as knee points.
Calendar aging is mainly influenced by the design, and driven by temperature, operating voltage, and floating
charging conditions.
Cycling aging is mainly influenced by the design, and driven by frequency, depth of discharge, and the
charging rate. Since stationary batteries are typically in float applications, cycle aging data is not often
provided. A battery with a good design can handle a certain amount of cycles and that is dependent on the
depth of discharge (DOD). The deeper the discharge, the fewer cycles a battery can handle. For example,
a VRLA battery for stationary standby applications from a reputable OEM can handle 100 cycles at 80% DOD,
190 cycles at 50% DOD, and 500 cycles at 20% DOD.
3.3.3.1 Sulfating
Sulfating on the plates of the cell occurs due to undercharging. Undercharging occurs whenever the current
passing through the cell is insufficient to offset self-discharge. For batteries in float service, this corresponds
to low float voltage. This also can happen to spare cells stored for extended periods with no or insufficient
charge.
Sulfated batteries are basically partially discharged/recharged batteries and therefore have reduced capability
or performance. If allowed to remain in a partially recharged condition for an extended period, sulfated
batteries may suffer irreversible damage, requiring replacement. If recognized in its early stages, sulfate can
be removed by boosting or equalizing the affected cells.
Table 2. Visual Indications and Likely Causes for Flooded Lead Acid Batteries
Test Visual Indication Failure Mode
Jar Internal An excessive amount of shiny crystals on the Undercharging
plates, which indicates sulphation
Excessive gassing Overcharging (check the float voltage)
An accumulation of spongy lead material on the Overcharging
top and sides of negative plates
Grid cracking or plate expansion Aging
Excessive sediment or shedding at the bottom of Aging
jar
Jar External Split or bent post seals Internal corrosion
Post corrosion Indicates the electrolyte is reacting with the lead
to corrode the post, which is generally due to
poor design and/assembly
Damaged or missing flame arrestor caps Flame arrestor caps are in place to prevent the
hydrogen inside the batteries from igniting.
Damaged flame arrestor needs to be repaired or
replaced by following proper procedure.
3.3.4.1 Dry-Out
The recombination process in a VRLA battery is self-regulating and can result in minimal loss of water from
the electrolyte. Other processes also can contribute to water loss:
• Normal corrosion of the battery plate
• Periodic venting of gases due to battery overcharging
• Evaporation of water vapor through the seals, pressure-relief valve, and battery case
If the electrolyte loses too much water, battery capacity is reduced. Excessive water loss also can create
large voids in the electrolyte, increasing the battery’s internal resistance and possibly leading to thermal
runaway. Thermal runaway can generate enough heat to rupture the battery case and, in extreme cases, result
in an explosion.
3.3.5.1 Over-Discharge
Over-discharge of a lithium-ion battery occurs when a cell voltage falls below a critical minimum, which then
allows copper from the negative foil to dissolve into the electrolyte. Upon recharge, the copper comes out
of solution to form micro-shorts, rending the cell inoperable.
3.3.5.2 Overcharge
Charge current is generally controlled by the battery management system, but control failures or improper
system setup can result in excessive charging current and cell damage (i.e., overcharging). Moderate level
of overcharging typically results in more rapid aging while prolonged overcharging can cause lithium-ion
battery cell to accumulate in the form of dendrites at the surface of an intercalation negative electrode leading
to internal cell short circuits.
3.3.5.3 Overvoltage
Overvoltage means charging the battery at the voltage level above the design limit. Overvoltage charging,
while is normally controlled and prevented by the BMS, can lead to oxygen evolution from the positive,
decomposition of the electrolyte and catastrophic failure including thermal runaway. Overvoltage charging
is generally caused by BMS control failure or improper system setup.
Table 3. Tests and Failure Modes for Lead Acid and Nickel Cadmium Batteries
Test Comment Failure Mode
Electrolyte Exposure of battery plates above the electrolyte Dry-out, low level, or overfill. Rate of change in
levels level can lead to rapid cell failure anddestruction. the electrolyte level can be used to identify
Electrolyte leaks can cause a battery short potential need for replacement of a cell.
circuit.
Individual Cell Operation of batteries outside the manufacturer’s Low-voltage cells: A cell voltage consistently
voltages range may lead to loss of capacity, sulfation, below normal float condition and not caused by
accelerated grid corrosion, and reduction of life elevated temperature of the cells indicates that
expectancy. may require cell replacement.High voltage cells:
Individual cells may exhibit a high voltage shortly
after installation and should come into line with
the others as they lose excess water and
approach fully recombinant state. Prolonged
operation above the cell’s high voltage limit can
has a detriment effect such as thermal runaway.
Ripple Ripple is the AC component of a system’s Poor charger design and/or failed filtering
charging voltage imposed on the DC bus. A high components of the charger.
ripple component can cause battery to cycle at
the ripple frequency and result in heating,
reduced life expectancy, possible thermal
runaway, and battery gassing, and dry-out or
excessive water topping. Many UPS systems in
the market today have eliminated capacitors as
a standard feature to reduce cost and footprint.
This essentially introduced excessive harmful
A/C ripple currents and therefore shorter life
span of batteries, particularly for VRLA batteries.
Flooded batteries can tolerate more ripple
content than VRLA batteries because higher
electrolyte volume helps cooling and improving
their capability to better withstand long term
ripple
Float voltage The correct battery float voltage at the battery Wrong setting of charger output voltage
terminal is critical and must be within
manufacturer’s recommended limits. Overvoltage
will cause excessive gassing and drying of the
electrolyte and also will contribute to potential
thermal runaway.
Float current The float current of a fully charged battery will Zero float current: a battery or connection in the
depend on design feature of the battery and its string is openExcessive float current: potentially
internal condition. shorted cells in battery. For lead acid battery
(vented or VRLA), a rising trend of the float
current can also indicate potential thermal
runaway resulting in potential excessive
hydrogen emission and fire.
Internal ohmic The measurement of internal ohmic when Cell degradation, requiring further evaluation or
compared with an established baseline may replacement
provide information about battery internal
condition at certain degree. It is used to identify
cells that require further evaluation. Internal
ohmic values are useful as a trending tool. The
readings without the benefit of baseline data are
of limited value.
Inter-cell To identify high-resistance connections leading to High-resistance or loose connections. Without
connection overheating. corrective action such as retorquing or cleaning
resistance the contact surface area, battery system can
experience excessive voltage drop or heat
damaged/melted terminal during discharge.
120%
100%
80%
Capacity
60%
40%
20%
0%
0 2 4 6 8
Years
Fig. 4. An example of VRLA battery with design life of 5 years in a controlled temperature environment
It is desirable for comparison purposes that the capacity tests be similar in duration to the battery design
duty cycle. Examples of typical designed run-times for different applications are as follows:
A. Data processing UPS batteries: 15 minutes
B. Industrial (process control) UPS batteries: from 30 minutes to several hours, depending on application
C. Telecommunication batteries: 4 to 12 hours
D. Switchgear batteries: more than 3 hours
When the capacity test is performed with a shorter duration, the discharge current should be determined
based on the capacity table provided by the manufacturer (see Table 4 for an example) with the selected test
duration.
For example, in a substation, a battery bank is designed to operate for 8 hours as the duty cycle. A full-duration
capacity test is performed with a duration of up to 8 hours. In the event a full-duration capacity test is not
performed, some vendors using the actual capacity rate tables from the battery manufacturer will perform a
3-hour test at the 3-hour-rated discharge current per the manufacturer’s rate table. This is acceptable only
if the DC bus and intercell connectors, etc. can tolerate the higher current for 3 hours. See IEEE 1188, IEEE
450, and IEEE 1106 for more details on capacity testing.
would otherwise have to be performed manually. These systems can provide warning for serious out-of-
tolerance conditions in near real time. The limitations of battery monitoring systems include lack of information
from visual inspection and capacity tests.
• 23% of losses due to inherited design issue in DC systems. Note: these losses are exclusively from
power generation occupancy.
• 20% of losses due to lack of adequate maintenance.
• 17% of losses due to aging.
• 7% of losses due to excessive battery room temperature.
• 6% of losses due to loosen connections at battery system.
• 27% of losses due to miscellaneous issues such as manufacturing defects, human errors, external cable
failures, inverter failure, etc.
4.0 REFERENCES
4.1 FM Global
Data Sheet 1-2, Earthquakes
Data Sheet 1-40, Flood
Data Sheet 5-33, Electrical Energy Storage Systems
Data Sheet 8-1, Commodity Classification
4.2 Other
Institute of Electrical and Electronic Engineers (IEEE):
• IEEE 450, Recommended Practice for Maintenance, Testing and Replacement of Vented Lead-Acid
Batteries for Stationary Applications.
• IEEE 485, Recommended Practice for Sizing Lead-Acid Batteries for Stationary Applications.
• IEEE 1106, Recommended Practice for Installation, Maintenance, Testing and Replacement of Vented
Nickel-Cadmium Batteries for Stationary Applications.
• IEEE 1115, Recommended Practice for Sizing Nickel-Cadmium Batteries for Stationary Applications.
• IEEE 1188, Recommended Practice for Maintenance, Testing and Replacement of Valve-Regulated
Lead-Acid Batteries for Stationary Applications.