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Inspection and test data analysis

Inspection and test data analysis. John Polenz. 06/11/2017. Supervisor Battery Technical Support - Vertiv. Data collection. Why collect the data if you aren’t going to do anything with it - Except file it!. discussion. Preventive Maintenance Inspection Data

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Inspection and test data analysis

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  1. Inspection and test data analysis John Polenz • 06/11/2017 • Supervisor Battery Technical Support - Vertiv

  2. Data collection • Why collect the data if you aren’t going to do anything with it - • Except file it!

  3. discussion • Preventive Maintenance Inspection Data • Consistent readings taken and recorded • Baselines established • Analysis of the data • Single report data analysis • Capacity Testing Data Analysis • Data recording • Unit and system data recording • Final analysis

  4. Data analysis • So many times with battery analysis – • IT DEPENDS! • ASK Questions to help get the answers: • Was the battery recently cycled? • How long has the value been that way? • Is it recovering or getting worse? • Has anything changed that could impact the battery? • Have any corrective measures been attempted? • Have you verified system readings at the battery – not at the charger? *Additional Notes

  5. PM Inspection DATA • Collecting Consistent readings! • Getting the right readings! • Importance of test equipment lead placement consistency • Different technicians will place test leads differently • Can negatively impact readings • Can impact trending • Misleading on actions to take *Additional Notes

  6. Establish ohmic Baselines • Trending is best method *Additional Notes

  7. Establish baselines • Establish Proper Baselines - Thresholds • Voltage • Internal Ohmic • Temperature • Ambient/unit • System Float • Unit float • Specific gravity *Additional Notes

  8. Proper baselines Example: 7500 = 11250 (50% above first reading) 3750 = 5625 (50% above 6 months reading) Incorrect baselines can mask potential concerns! *Additional Notes

  9. Specific gravity data analysis Can be hard to make correct determination *Additional Notes

  10. Temperature swings *Additional Notes

  11. Validation of data Float = 2.179 v/c Actual battery float requirement 2.25 v/c *Additional Notes

  12. Validation of data • Investigation for: • Unit Float issues • Internal Resistance increase Actual float should be 535 VDC Nom. Float – 2.23 v/c Recorded – 2.246 v/c At the battery – 2.245 Exceeds manufacturer recommendations *Additional Notes

  13. Take the Readings and move on • Sometimes it is plain • Sight! *Additional Notes

  14. Don’t only record the data Low voltages Lower temperatures Low float setting *Additional Notes

  15. Alarm triggers *Additional Notes

  16. Single data set analysis • Improper threshold • It did not identify • Suspect units! • Quick visual look! The 3 units all exceed 50% above baseline using present data set *Additional Notes

  17. Single data set analysis *Additional Notes

  18. Contributing factors can be identified with analysis Voltage drop Over charge Under charge *Additional Notes

  19. Lack of data for evaluation *Additional Notes

  20. Capacity test Analysis • Capturing useable data • Capturing only system level vs. unit level • Voltage, temperature, current, time • Where the data is collected is important • UPS application – at the battery and at the UPS to aid in system design verification, *Additional Notes

  21. Data analysis • Don’t assume the battery has failed - • Didn’t make time • Didn’t meet the ECV requirement • Cell/unit dropped out early • Example: • The following discharge testing results were observed: • On an 11 minute backup time rating, the batteries ran for approximately 16.5 minutes. • The batteries supplied over 100% capacity using the industry standard IEEE 1188, rate adjusted calculations. • At the 15 minute discharge point (before voltage drop-off) the lowest battery voltage was 9.871 • The test ran until the end cell voltage reached 1.60 volts/cell and the batteries supported an average load of 55.66kw for 16.5 minutes. *Additional Notes

  22. Verifying report alarm thresholds Default software setting to 1.67v/c Changed to 1.50 v/c *Additional Notes

  23. Test data • Data logging helps to make analysis easier and quicker *Additional Notes

  24. Uniform test results *Additional Notes

  25. Do not make battery performance assumptions till the data is analyzed • Analyze the data collected • Verify the load applied to UPS/battery • Verify published performance specification for the battery • Verify ECV cutoff setting • Verify temperature of the battery during the test • Calculate the battery capacity per IEEE 1188 *Additional Notes

  26. Summary • Some data is better than none • The more data the better for evaluation • More data provides better trending • Better trending leads to better prevention to failures • Baselines need to be established properly • Data analysis can help to identify: • Charger issues • Environmental concerns • Failing battery • Voltage drop identification • Improper maintenance practice *Additional Notes

  27. Thank you for your attention!

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