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Battery Research & Testing is the world’s leader
in developing the IOVR™ process for restoring lost capacity in VRLA cells.
The IOVR™ (internal ohmic value recovery) process entails the analyzing the
internal ohmic values of the cells as compared to known “good numbers”,
replacing the lost water from each cell as needed, and the replacement of
the originally installed vent assembly with a vent assembly that has a
Philadelphia Scientific Microcat Catalyst attached. Of course the process
is more detailed than this brief explanation, but it is easily performed
and in most cases can be performed without ever taking the battery out of
service.
Through the IOVR™ process we can recover lost capacity in
any structurally sound 20 VRLA battery. We have recovered lost capacity
from under 5% to over 90% and have returned many systems to 100% of their
original capacity. If the cells are relatively new and have not yet been
negatively affected, we can just replace the existing vent assembly with a
vent assembly with the MicroCat attached, and prevent the early failure of
the cells.
The actual amount of capacity recoverable is dependent
upon the extent lost, reason for the capacity loss, and the length of time
the cells have been in service. It is important to remember that VRLA
cells can have very different failure characteristics than flooded lead
acid cells. Just because a VRLA cell is less than 80% of its rated
capacity does not mean that it is in imminent danger of a sudden collapse,
or that it must be replaced. As long as the battery can perform its
function for the amount of time required, and it is internally
structurally sound, it can still be used. With the reduction in loads at a
number of sites, a battery could be at less than 50% of its originally
rated capacity, but still be able to protect the site, and function for
many more years.
There are two different but related reasons for a
VRLA battery to fail to perform. They are distinctly different but
directly related. They are “dry-out” which is sometimes called “lack of
compression”, and “Negative self discharge”. The “dry-out” can be the
result of a variety of reasons such as overcharging at higher than
recommended float voltages, or at higher than recommended temperatures, or
overcharging of the positive plates which causes increased current, or
undercharging of the negatives. Whichever the cause or causes, the result
is that water is driven out of the cell as a gas, and the contact between
the plates is reduced. This reduced contact affects the capability of the
cells to deliver their capacity. The Negative self discharge is the result
of too much of the oxygen that is generated at the positive plates is
getting to the negative plates and causing the negatives to discharge more
than they should. The catalyst robs just enough of this oxygen to help
maintain the proper plate potentials. By keeping the negative plates
properly charged this keeps the positive plates from being overcharged,
thereby reducing the required charge current, which reduces the abnormal
positive plate growth, and which also prevents thermal
runaway.
Contact us to discover our partners in this process across
the USA and Canada.
The IOVR™ Process:
As everyone knows,
most 20 year VRLA design batteries have not lived up to their marketing
hype. In fact most will fail a capacity test within 4 to 7 years of age
under ideal conditions. Batteries that are under less than ideal
conditions will fail much sooner. Of course the battery manufacturer will
supply a warranty adjusted replacement battery once you have performed a
capacity test and proven that the battery is at less than 80% of its rated
capacity.
FOR A PRICE THAT IS!
Every reputable battery
manufacturer will honor the warranty on a failed battery, and will
calculate the amount of the warranty months used and give you a price that
is based upon your original purchase price. For example let’s say you
purchased a 48 volt battery with an 8 hour rating of 4,500AH. Let’s also
say that you purchased this battery system as a turn key installation with
the battery, freight and labor as one number. Let’s use $58,000 as the
project cost ($46,000 battery the rest freight and labor). Now let’s
imagine you are 5 years (60 months) along and the battery system fails to
perform and with a subsequent controlled load test you discover that the
battery is less than 80% of its rating. You need the battery to be above
80% of its rating to carry your loads for the required amount of
time.
You contact your manufacturer and supply them with your
information, and they will sell you a new battery at @ $11,500 plus
freight. This is a reasonable price. But you also will have to pay freight
@ $1,500 ??, and you will have to pay for someone to remove and dispose of
your old battery and install a new one. Since the old cost of $10,500 was
for a new installation, what will a price to remove a battery and install
another one be? Let’s use $15,000 for this example.
Your real cost
to replace that battery is going to be $28,000. This price will vary all
over the place depending upon how much freight, what the labor costs are
where you are located, and if a temporary battery is required during the
replacement process.
Now imagine doing that same process two or
three times during the life of the battery.
The customer gets to
pay, and pay, and pay some more. What’s wrong with this picture? Nothing,
IF you are a manufacturer and everything if you are a user.
Heck,
in some cases the manufacturer could give you the new battery system
including freight and it could still cost over $20,000.
With the
installation of a catalyst in a new cell or the performing of the IOVR™
process, you can have a chance to actually obtain what you paid for, and
only spend typically between $50 and $100 per cell, depending upon the
layout and location. It is your decision, but which makes more economic
sense.
Try your
own numbers in this Excel spreadsheet.
Cost of an unexpected failure:
What
does it cost you or your company if the battery system that is protecting
your equipment fails to perform as expected when it is called
upon?
In a power plant, if the system is protecting the generator,
the bearings can be ruined, which means expensive repairs and loss income,
and possibly having to purchase power on the spot market to supply your
customers. If it fails to function and there is a fault on a line, the
transformers can be damaged, or a line can be destroyed. Needless to say
that your customers who might be left in the dark will be
upset.
With a UPS system, the computers would crash, information
could be lost, along with revenue, and customer confidence could diminish.
Does 7 by 24 have any meaning here?
With a communication site if
the battery fails when called upon, all transmission of voice or data is
lost. Sometimes it takes a substantial amount of time to get some
equipment back up and functioning properly. Revenue is lost, and customer
confidence is reduced. With some outages the FCC requires a
report.
In a manufacturing or process plant, the battery failure
can cast lost production, the need to replace or clean whole piping
systems, or the loss equipment.
All of these failures can be
prevented.
General information:
Every battery model
has an “ideal” internal ohmic value. This is a range for each cell model,
that if the ohmic values are within this range, the battery most likely
will function as advertised. There are also ranges that will almost
positively mean that the battery will not function properly.
We in
conjunction with our partners throughout the USA and Canada have compiled,
calculated, and developed a data base of values for most model cells that
are manufactured today. We also have the means to calculate the
“approximate” values for any new cell designed.
The IOVR™ process
starts with a complete and thorough battery inspection with key emphasis
placed upon internal ohmic values, charge current and structural
integrity.
The charge current in any VRLA cell ideally should be
less than one-half amp per 1,000 AH at the eight hour rate. Values above
this are an indicator of problems.
Battery Research & Testing
vent assemblies can restore the plate potentials to their proper values,
thereby restoring lost capacity.
Battery Research & Testing
vent assemblies when installed in good cells will help to maintain the
proper plate potentials, plus will help to prevent dry-out and thermal
runaway, and help you realize the life that the manufacturers advertise.
Click here for details on
battery catalysts and maintenance tools
Wholesale pricing for large
quantities and US Military orders.
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