Battery Safety and Design Manual for

Payloads

Battery Safety and Design Manual for

Payloads

presented byJerri S. Ling

September 13, 2004

presented byJerri S. Ling

September 13, 2004

Battery community suggests that the JSC battery handbook needs to be updated (June 2001).

RMO submits a Code Q RTOP proposal to update the JSC battery handbook (Sept. 2001).

RTOP is approved Oct. 2002 , however payload community recommendations for updates differ from PSRP recommendations (Jan. 2003 to March 2003).

Decision to make document internal to GRC (March 2003).

Initial information gathering (Best Practices, Lessons Learned, text books, graphics, vendor sites, etc) (March 2003 to Sept. 2003).

GRC-M8100-006 Battery Safety and Design Manual for Payloads completed (July 2004).

Background

Overview

DOCUMENT PURPOSE - Provides a compendium of quality and safety-related best practices and reference information for design, and testing of cells and batteries used in space flight applications.

DOCUMENT SCOPE - Intended to provide project managers and design engineers with key elements of battery selection, factors to consider during the design/development phases, and clarification of the safety review process for batteries.

Used by payload designers in conjunction with the JSC Battery Handbook (JSC 20793).

Allows Project Management to more accurately map out required resources based on battery-related tasks that need to be performed.

Contents

CHAPTER 2 - REFERENCES

Applicable Documents

NSTS 1700.7B and it’s ISS Addendum - Safety Policy and Requirements for Payloads

NSTS/ISS 13830 - Payload Safety Review and Data Submittal Requirements

JSC 20793 - Manned Space Vehicle Battery Safety Handbook

GRC-0510-002 Space Assurance Requirements and Guidelines (SARG)

Others

Contents

CHAPTER 3 - CELL/BATTERY DESIGN CONSIDERATIONS

Charging Batteries

Preventing Battery Short Circuits

Voltage Reversal

Thermal

Preventing Leakage

Preventing Improper Insertion

Contents

CHAPTER 4.0 - FACTORS AFFECTING BATTERY PERFORMANCE

Voltage Level

Discharge load

Discharge mode (constant current, constant power, constant load, etc.)

Temperature during discharge

Service Life

Voltage Regulation

Charging Voltage

Battery Age/Storage Conditions

Battery Design

Contents

CHAPTER 5.0 - BATTERY SELECTION AND APPLICATIONS

CHAPTER 6.0 - CELL/BATTERY TEST PLANS

Purpose of Test Plan

Test Plan Outline

Test Plan Checklist

Contents

CHAPTER 7.0 - GROUND TEST CONSIDERATIONS

Hazards and Precautions for Battery usage

Battery Test Facility Checklist

Safe Handling RequirementsLead-Acid Batteries

Nickel-Cadmium Batteries

Lithium Batteries

Emergency ProceduresExposure to Electrolyte

Leakage/Venting/Temperature increase

Cell Rupture

Lithium Cell Fires

Disposal Procedures

Contents

CHAPTER 8.0 - FLIGHT SAFETY REQUIREMENTS

Overview of Flight Safety Review Process/Requirements Summary

General Hazards and ControlsStructural

Gas Evolution

Elevated Pressure

Electrolyte Leakage

Short Circuits

Circulating Currents

High Temperature

Overcharging

Safety of Specific Battery TypesLithium Ion, Nickel-Cadmium, Nickel Hydrogen, Silver-Zinc, et al.

Contents

CHAPTER 9.0 - CELL SCREENING TESTS

Automated Testing Equipment

Coulombic Efficiency

Polarization Testing

Open Circuit Decay Test

Tailoring Screening Tests for Specific Cells

Thermal Tests

Contents

CHAPTER 10.0 - BATTERY TEST PROGRAM

Engineering/Certification Tests

Battery Level Performance Testing

Abuse Tests

Qualification Testing

Flight Acceptance Testing

Payload vs. GSE Usage and Testing

Recommendations

Contents

CHAPTER 11.0 - OTHER ENERGY STORAGE DEVICES

Fuel Cells (description of various types), Flywheels

APPENDIX A - LESSONS LEARNED

APPENDIX B - THEORETICAL VOLTAGE/CAPACITY TABLE

APPENDIX C - SUMMARY OF BATTERY BEST PRACTICES

Glossary of Terms/Acronym List

8100/Risk Management Office8100/Risk Management Office

Document available from GRC BMSDocument available from GRC BMS