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Arduous applications
EnerSys supplied a complete set of
new batteries, chargers and related
equipment. This included 100 of its
advanced ‘Perfect Plus’ batteries (80V
PzS620Ah) for the luggage tugs. These
batteries are ideal for arduous and
intensive applications because they
offer a high level of power with longer
running times and improved reliability
compared with conventional batteries.
Advanced components in the positive
plates promote higher efficiency
discharge. The size of the positive and
negative plates is optimised for the cell
box which means the batteries have
higher capacities than conventional
designs with the same dimensions.
For the push-back tractors EnerSys
supplied 90 of its powerful Ironclad
batteries (80V PzQ688Ah). Designed
for heavy-duty applications these
incorporate tubular positive electrodes
with greater surface area than
traditional flat-plate designs and a
higher-than-average-density electrolyte.
This helps deliver more power with
higher discharge rates and up to 15%
longer running times than comparable
models. They are particularly suited to
intensive applications where operators
such as TGS want to extend the period
between recharges and minimise the
number of battery changes.
The new charge-and-change building
was designed by EnerSys from the
ground up for efficient operations.
It incorporates 100 of the advanced
Hawker LifeIQ high frequency
programmable smart chargers. These
offer improved efficiency and lower
charging factor than conventional
models which results in reduced
energy consumption and lower carbon
footprint. They automatically detect the
battery’s level of discharge and only
supply the amount of power needed
to restore full charge before shutting
down. They have a real-time clock
which allows charging operations to be
scheduled during less expensive off-
peak periods. Equalisation charge can
be started when convenient and real
dates programmed for each event.
EnerSys supplied 200 of its innovative
WiIQ wireless battery monitoring
devices. Mounted on the DC cable of
the battery these track metrics such
as charge, temperature, voltage and
electrolyte level in real time and upload
data to the main battery management
system. The advanced capabilities of
the batteries, chargers and monitoring
systems combine to ensure optimised
charging profiles for the fastest cycle
times, life-time reliability and lowest
energy consumption.
Battery charging and changing
operations are overseen by the
Hawker Life Network WiFi wireless
Battery Fleet Management system. This
analyses information from the batteries
and chargers, including data from the
WiIQ devices, to maximise performance
and efficiency. In this particular
installation the system is configured to
impose first-in-first-out battery rotation
so the best available battery is always
used. This helps to ensure that the
utilisation of all batteries is balanced
so that each one continues to deliver
reliable performance over its projected
working lifetime.
Inside the charging room two large
LED screens mounted on the wall
provide vehicle drivers with clear and
concise information including details
of the next available battery that they
should use. The system is configured
to sound an alarm if the wrong unit
is selected to promote a high level of
compliance with agreed procedures.
Managers can monitor the operation
from any computer with a web browser
and access a wide range of analytical
and reporting tools to assess and
optimise fleet performance. They can
also configure the system to issue
alerts by email or SMS in the event of
predetermined events so that they can
respond proactively.
The remaining infrastructure inside the
battery building has been designed for
safe and efficient operations. Batteries
are exchanged using a dual over-head
crane which offers increased capacity
over the previous facility. The cranes
have 2.5 tonne maximum working load
and there is built-in redundancy so
that operations can continue during
scheduled or unscheduled downtime of
either unit.
The battery chargers are mounted on
a frame at head height. This removes
potential obstructions from the
floor, minimises the risk of damage
from collisions and affords easier
access during routine operations or
maintenance. Cables are short to
prevent them trailing on the ground.
Ancillary services including electrical
transformers, cabling and water pipes
were incorporated into the design from
the start and positioned to serve all of
the charging stations. An on-site water
treatment plant was installed to ensure
a continuous supply of deionised water
for the batteries for the automatic filling
systems. Epoxy coating on the floor
provides protection against accidental
spills of water or battery acid. Automatic
doors with infra-red sensors ensured
the building remains secure against
the elements while allowing easy
access for vehicles. The design also
included hydrogen detection and active
ventilation systems to maintain excellent
air quality at all times.
EnerSys has completed similar
installations for TGS at five other
airports in Turkey - Istanbul Sabiha
Gökçen International Airport, Ankara,
Antalya, Bodrum and Dalaman. The
company expects to provide facilities
for TGS at two more airports in due
course. It has also been commissioned
to complete a facility for another airport-
support operation at Sabiha Gökçen
International Airport.
51
Logistics Business Magazine | November 2015
BATTERY POWER