number 24 winter 2007/spring 2008 saft...number 24 winter 2007/spring 2008 saft international visit...
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SAFTINTERNATIONAL
VISITwww.saftbatteries.com
TECHNOLOGIES PAGE 6
Battery solutions for renewableenergy systems
Since the last edition of Saft International, Saft has experienced a period of strong growthduring which there have been exciting successes and some challenges.
Our major challenge over the past year has been rapidly rising and volatile raw materialprices, which the manufacturing industry in general and the battery industry inparticular has been faced with. Such huge increases have required Saft to adjust pricesand although this is never easy, I am pleased that our customers have generally under-stood the necessity of these actions and the impact that this has had on our company.
Saft’s major competitive advantage remains our technological leadership, and this is main-tained by a high level of R&D spend every year. The concrete results of this investmentare the many new contracts we announce for innovative projects using new technologies.
Energy storage for renewable energy systems is one particular focus of these efforts, but the telecomnetworks, aviation and defence markets, to name but a few, will also benefit from innovative batterysystems in the future.
Saft’s joint venture Johnson Controls-Saft was only created in January 2006, but has already madesome very important breakthroughs. The most significant is our announcement of the world’s firstseries contracts for hybrid vehicles using lithium-ion batteries. These first contracts for new genera-tion batteries are significant for the future of hybrid vehicles. The market potential is very large andJohnson Controls-Saft is now positioned as the leader in lithium-ion. The volume deployment of largelithium-ion batteries will also accelerate their availability for Saft’s traditional applications.
Saft intends to maintain and reinforce our position as world leader in high technology batteries, inorder to continue to support our customers’ development
I wish you a happy and successful 2008.
A bright future
John SearleChief Executive Officer Saft Groupe
Saft International _ A magazine for Saft’s customers and business partners. Editor-in-chief: Jill Ledger. Managing Editor: Catherine Jouatel. Texts: Graham Lord. Graphic design: D Parquet and ML Lanceau. Photo credits ©: Corbis UK Ltd/Jupiterimages. DR X, Saft. TENESOL - Total Energie.Independant Witness. Astrium. iStockphoto/Ravi Tahilramani. Thales Alenia Space. BAHRAT/P. Mathur. FMC Technologies. iStockphoto/Sean Locke. KTM Fahrrad GmbH. Hydrometer. Boeing. Statron. TELELIFT GmbH. Martin Adolfosson. By courtesy of StatoilHydro. Photo Icade. Courtesy of Flo Healthcare – all rights reserved. U.S Department of Defense. ALSTOM Transport/P.Sautelet. ALSTOM Transport/TOMA – C.Sasso. Lockheed Martin.
Saft Corporate Communication, 12 rue Sadi Carnot, F-93170 Bagnolet. Ph: +33 (0)1 4993-1707. e-mail: [email protected]
IN THIS ISSUE
Saft ramps upproduction in China
PV systemsenhanced by Li-ion storage
NASCAR drivers safer with Saft-powered “black box”
6
7
22
Innovative wind-power backed by Ni-Cd storage
Paris canal boats go green with Ni-Cd
20
12
Hospital AGVs Ni-Cd for efficiency and lower cost
Wi-Fi phone booths go for smart Ni-MH
Longer runtime for Ni-MH hospital workstations
Experimental e-plane takes off with Li-ion
High-power Li-ion meet Army’s vehicle needs
Low-maintenance Ni-Cdfor Paris tram
Saft helps break world rail speed record
Partnership in aviation battery technologies
18
Saft wins biggest U.S. satellite contract
Ni-Cd: top performancein mountain tunnels
50-plus Eurostarsatellites fly Li-ion
Back-up solutions for telecoms
24
14Li-ion and Ni-Cd meetstringent e-battlefieldneeds
Li-ion enhancessubsea oil technology
4
Saft partnership for e-bike technology
Primary lithium for long-life meter reading
16
Spacebusprogramme opts for flexible Li-ion
Saft winsUS quality awards
10
8
26
transmit data. Chinese regulations stipulatethat these batteries must last at least 6 years.
Saft’s primary lithium batteries “Made inChina” were rapidly approved by OEMcustomers. “Deliveries have been ramped upsteadily over the past year. Production hasgone from 1 to 3 shifts per day and we arelooking at 24x7 production by the end of2007”, says the subsidiary’s GeneralManager Pierre-Marc Leroy. “We startedwith 30 employees and this has grown to110. Things are really moving!”
Distributor Sonic is just as up-beat: “It isa positive move to manufacture in Chinabecause the absence of import taxes meanslower prices, and delivery is faster”, says
PAGE 4 SAFT INTERNATIONAL
STRATEGY
In a move to get closer to OEMs and provide better customer service, Saft hasmade a major investment in a new production facility in Zhuhai, China. Up andrunning since 2006, the plant mainly supplies primary lithium batteries formetering applications – Zhuhai is gaining market share in China and alsohelping to help meet demand in the rest of the world – and is delivering Ni-Cdrailway batteries as well.
Saft’s new manufacturing plant, in theZhuhai free-trade zone just over the borderfrom Macau, (about 100 km or 60 milessouth of Guangzhou, formerly Canton, and50 km west of Hong Kong), operated by awholly-owned subsidiary, Saft (Zhuhai FreeTrade Zone) Batteries Co Ltd, was inaugu-rated in May 2006. Saft chose this locationin Guangdong province – one of the mosthighly industrialized zones in the People’sRepublic of China – because of the excellentquality of its infrastructure, its proximity toexisting customers and its pool of skilledlabour. The purpose-built facility, built on a7,000-sq. metre site, includes brand-newmanufacturing lines using Saft’s latest technology.
Serving two markets
Saft is now present in two marketsoffering strong growth potential in China,whose economy continues to break growthrecords. These are primary lithium batteries,a segment where Saft is world leader andwhere local growth stands at about 20% peryear, and the booming market for railwaybattery systems, as China expands its infra-structure and launches numerous projectsfor subways and high-speed trains. Zhuhaihas already given Saft extra productioncapacity to serve China’s growing meteringmarket and the new plant also supportssales of railway batteries as well.
Metering batteries…
Production at Zhuhai got under way inApril 2006 even before the plant was inau-gurated and first deliveries (of LSG 14250primary lithium batteries for electricitymeters) were made to the subsidiary’sChinese distribution partner, Sonic, inAugust.
Modern electricity meters are oftenelectronic rather than mechanical. Theyoffer additional functions like remote orautomatic meter reading (without accessto the premises), meter condition moni-toring, fraud/tampering detection, multi-rate tariffs, etc. These meters needbatteries to operate and to store or
SAFT INTERNATIONAL PAGE 5
Managing Director Patrick Cheng. “But oursuccess is mainly due to the continuing focuson quality. Customers here have alwaysappreciated Saft’s long experience, but itwas vital to demonstrate to OEMs thatbatteries manufactured at Zhuhai meet thesame rigorous quality standards as those weimport from France. We have now gainedtheir confidence. Today we have over 200OEMs signed up and a market share ofabout 60% in this segment, up from 20% afew years ago, and our target is 70% nextyear. I think Saft has a big future”.
Zhuhai is part of Saft’s worldwide strategytoo: “The plant was set up to meet growingdomestic demand, but we are now startingto export as well, to help Saft’s lithium plantsin Poitiers and South Shields meet demandin the rest in the world”, adds Pierre-MarcLeroy.
…and railway back-up systems
As for railway battery systems, Saft’sChinese subsidiary regularly supplies
batteries produced in Bordeaux, but by lateNovember 2006 they were rolling off theZhuhai line as well, ready for the OEMacceptance process. Saft’s first customerhere was one of its traditional manufacturingpartners Alstom, which is expanding inChina.
Getting closer to Chinese customers byinvesting in a local production base was obvi-ously a good move; in June 2007 Saft won acontract from China’s leading rolling-stockmanufacturer, Changchun Railway VehicleCompany (CRC), to supply on-board Ni-Cdbattery systems for 24 new trainsets for theBeijing metro. The new CRC trains are dueto be in service for the 2008 Olympics. Thelow-maintenance battery systems, based onSaft’s compact and light-weight SRMrechargeable rail batteries, will provide reli-able back-up power to support emergencylighting and air-conditioning in the event of aninterruption to the main power supply.
Expanding customer services “This new plant is firm evidence of Saft’s long-termcommitment to the Chinese market”, says Pierre-Marc Leroy.
“It enables us to demonstrate a significant increase in local added value by
manufacturing and assembling battery systems in China, using locally-sources
mechanical and electro-technical components. In future, Saft’s own Chinese
engineers will be able to provide a full range of support services including
installation, commissioning and training”.
Local presence,global reach With the new Zhuhai facility, Saft
now has 16 manufacturing sites.
The company has a truly global pres-
ence, with about 3,900 employees
working in 18 countries and a
production and sales network that
enables Saft to serve customers all
over the world.
Saft’s new plant in Zhuhai nowsupplying batteries to the fast-growingChinese market.
today’s PV systems (mainly stand-alone units)are battery supported, but Saft believes thatstorage will make a major contribution toworldwide integration of PV systems.
Saft has supplied Li-ion battery systemsas a partner in five currently running orplanned projects and will continue to developthem to supply alternative solutions.
PAGE 6 SAFT INTERNATIONAL
TECHNOLOGIES
Saft Li-ion batteries foradvanced PV systems in
Guadeloupe Saft has joined forces with Tenesol,Technofi and French power utilityEDF on a two-year project to testthe technical and economic feasibilityof using Li-ion battery storage withgrid-connected photovoltaic (PV)systems for residential and smallcommercial buildings. The aim is to enhance theefficiency of future PV solutions.
The main objective of the project, which isbacked by the French Environment andEnergy Management Agency (ADEME), is tostudy the optimal use of solar energy inorder to avoid the current use of fossil fuelturbines and to validate the potentialenhancement of energy quality and dispatch-ability due to battery storage. The secondaim is to gain operational experience so asto determine the optimal parameters forfuture grid-connected PV systems manage-ment.
In Guadeloupe, Saft and solar-panelmanufacturer Tenesol will deliver 14 PVsystems, each made up of a set of solarpanels together with 250 V, 11 kWh Li-ionstorage batteries.
Looking to the future
Renewable energy systems make excep-tional demands on storage batteries, whichhave to cope with difficult operating condi-tions, tough cycling and the generally inter-mittent character of the power supply andload conditions. Saft is playing a leading rolein developing Li-ion solutions that matchthese requirements. One result of research
here has been the unique Intensium Flexconcept, which will be tested during theGuadeloupe project.
Development of advanced storagesystems will be a key factor in boosting PVuse. The market is currently growing bymore than 30% annually and the IEA fore-casts that PV systems will meet 20% ofworld electricity demand by 2040. Grid-connected systems will account for thelargest share of this market. Very few of
Li-ion battery storage for more efficient renewable energy systems
Under the weight of public opinion opposed to uncontrolled use of fossil fuels,
governments and industry alike are moving to develop and improve renewable
energy systems such as solar and wind power. One of the key factors in making
renewable systems more efficient is the ability to store energy to warranty
energy supply and power quality with a flexible energy management. Batteries
are one of the answers, and Saft, which is a partner in both wind and solar
power projects, is a major part of that answer.
PARTNERSHIP
Saft partners withIndependent Witness(IWI Global) for betterNASCAR driver safety
Independent Witness, a specialist in incident data recording (IDR) technology, haschosen Saft LST 14500 lithium-thionyl chloride batteries as the primary powersource for its Witness™ Asset ProtectionSystem for auto-racing applications. TheWitness “black box” records time, date,force and direction of impact during a crashand the data is used to design safer racecars and reduce the risk of critical injury.
More power, longer life
The battery-powered device must operatein a variety of temperatures for extendedperiods while maintaining absolute accuracyof reporting, so it needs a premium powersource. Standard AA-size alkaline cells didnot meet the standards IndependentWitness demanded, so Saft proposed abattery pack that fits the existing space whileproviding more than double the power and alonger lifetime.
Starting in 2002, every NASCAR racecar has been equipped with the Witness“black box”. After an incident or at theconclusion of the race, data is analyzed sosuch that NASCAR can design safer carsand more effective safety devices. Numerousother motor-sport organizations useIndependent Witness technology, includingthe World Rally Championship, a division ofFormula 1 Racing, Grand AM, GM Racingand among others Ford Racing.
power Witness “black boxes” that have beenadapted to monitor NASA’s space shuttleboosters, to equip public transportation,taxicab and product delivery fleets and torecord strong motion seismic activity onstructural assets. Going beyond safetyenhancement, “black box” data is regardedas accurate and reliable enough to be usedin deciding insurance claims and variouscourt cases.
Stringent quality and reliability were the key when Saft batteries werechosen by Independent Witness to power its auto-racing “black box”. The result will be safer NASCAR race cars and reduced risk of criticalinjury from accidents.
SAFT INTERNATIONAL PAGE 7
The WitnessTM “black box” [see inset picture] is mounted inthe frame of the car where it continually monitors andrecords vital safety information. This data is ultimatelyused in the design of new race car safety features.
Quality and reliability
“As the exclusive provider of IDR tech-nology to NASCAR’s top three sponsoredseries, it is critical that our products neverfail”, says Scott McClellan, CEO/Founder,Independent Witness. “We selected Saftbatteries to meet our stringent quality andreliability standards to ensure that weprovide our customers with a premium datarecording device”.
In addition to motor sports, Saft batteries
PARTNERSHIP
The Eurostar series platform has beendesigned with geostationary (or GEO) tele-coms applications in mind. Its modulardesign enables a generic architecture to becustomized to specific customer require-ments. A Eurostar-based satellite was thefirst communications satellite to feature fullydigital electronics and the first to success-fully demonstrate on-orbit performance of Li-ion batteries, “a major technological break-through in satcoms power”, according toAstrium. The batteries’ cell modules weresupplied by Saft.
“The on-orbit performance of Saft’s Li-ionmodules was first demonstrated during theoperations of the Eutelsat W3A satellite,”observes Alain Brunschvig, Eurostar SupplyManager for Astrium. W3A was launched inMarch 2004 and since then, four moreEurostars have been successfully operatingwith Li-ion: Hispasat’s Amazonas, Eutelsat’sHot Bird 8 and two military GEO. Saftsupplies the modules to Astrium’s Toulousefacility, where they are made up intobatteries.
“Saft has a very good product,” adds AlainBrunschvig, “with excellent end-of life potential,which is crucial to the success of long-lifemissions of 15 years or more.”Good thermal management of the batteryhas been achieved thanks to the cooperationbetween Astrium and Saft.
He also points out that the spacecraftwith Saft’s Li-ion technology have nowreached the historically crucial on-orbit lifetime of three years, which will encourageother operators to choose the technology.
Staircase to the heavens:Eurostar leading the way
SAFT INTERNATIONAL PAGE 9PAGE 8 SAFT INTERNATIONAL
More andmore satellitemakerschoosing Saft Li-ion
Saft is the world’s leading developer andsupplier of rechargeable power solutions forthis critical application with its toughcharge/discharge cycles, with an impressiveseries of launches in 2006-2007.
Saft batteries are providing the on-boardpower for the new Calipso LEO Earth obser-vation satellite, based on an Thales AleniaSpace Proteus platform launched in August2006 on a 3-year polar-orbit mission. Thisone has been followed by Corot (based onthe same plate-form) launched in December06. Three more Saft-powered Proteus plat-forms will be launched by end-2008.
Revenue-generating payload
Thales Alenia Space also chose Saft back-up power for their Syracuse 3B (following the3A launched in 2005) secure militarycommunications satellite launched by anAriane 5 (itself using Saft batteries) for theFrench Defence Ministry.
Also in August 2006, Saft Li-ion batteries
More and more satellite makers areswitching to Li-ion batteries that store thesame amount of energy as Ni-Cd or Ni-H2batteries in much smaller and lighterpackages. This allows them to producemore powerful satellites by dedicatingmore of the crucial mass to revenue-generating payload.
went into service aboard the most powerfulsatellite ever ordered to serve Europe: theEutelsat’s HOT BIRD™8 GEO broadcast satel-lite based on Astrium’s Eurostar E3000 plat-form. The Saft cell modules are integratedinto Astrium batteries.
In the same month, Koreasat 5, basedon Thales Alenia Space’s 4000 C1 platform,was launched from the Odyssey platform. Korea’s first hybrid civil and military commu-nications GEO satellite has Saft Li-ionbatteries for back-up when its solar panelsare eclipsed. The batteries are in 3 packseach made up of 10 modules in series, witheach module having 3 VES140S cells inparallel.
In October 2006, Saft high-performanceLi-ion batteries were aboard when the OptusD1 GEO communications satellite built byindustry leader Orbital Sciences Corp. waslifted into orbit from Europe’s Spaceport inFrench Guyana. In July, Orbital had alreadybecome the first to launch Saft’s advancedLi-ion technology into geosynchronous orbitaboard a U.S. government satellite, and it
plans five more Saft-powered satellites overthe next two years.
In April 2007, the Italian Space Agency’sAGILE orbiting gamma-ray and hard X-rayobservatory, built by an international consor-tium led by Carlo Gavazzi Space, SPAbecame the first LEO satellite to be poweredby a battery system based on Saft’s MP176065 Li-ion cells.
In October 2007, Ariane 5 performed adual launch with two Orbital ScienceCorportation Star 2 Satellites: Optus D2 andIntelsat 11 (previously called Panamsat 11).The two satellites are powered with a Saft Li-ion 4P10S VES140.
In December 2007, Ariane 5 performeda launch with Li-ion battery powered telecom-munication satellite Horizon 2 which wasmanufactured by Orbital SciencesCorporation and belongs to Intelsat.
Based on several years of successful collaboration onlithium-ion (Li-ion) batteries for space, Astrium hassigned a long-term agreement with Saft for use of thetechnology on the Eurostar E3000 platform. Some50 Eurostar-series satellites have been ordered so far.
Strategic power orientation
“We completely support Saft’s Li-ion solu-tions for GEOs,” says Alain Brunschvig. “Theybring high benefits in terms of capacity, foot-print, power dissipation and weight for largespacecraft. But we’ve also been migratingthem to smaller satellites with just 3 or4 kW of power.”
Regarding his company’s relationship withSaft, he underscores his satisfaction withthe cooperation and communication betweenthe two partners. “We’ve optimized theutilization of Saft cell modules to obtain thesmallest, lightest possible on-board powersource,” keeping equipment to the “strictminimum”. Li-ion battery technology is espe-cially attractive to high-power satellites (withover 10 kW of power requirements)because of the lower volume and massrequired for power storage.
The E3000… and soon, Alphabusand recently Arabsat and Yahsat
The latest member of the Eurostarseries, the E3000, has already been chosenby a number of satellite operators: Eutelsat,Hispasat, Inmarsat, Intelsat, Paradigm, SESAstra, Telesat and recently Arabsat andYahsat. Successfully introduced in orbit in2004, it is setting new standards, in partdue to its Saft Li-ion technology. TenE3000s have been launched so far, of whichfive are powered by Li-ion, and twelve moreare on order. The Eurostar E3000 platformsfeature extensive mass and power scalability.Their enhanced payload accommodationmakes them a highly efficient, single-productsolution across the whole scope of communi-cations missions, from conventional mid-range to the most sophisticated.
In addition, jointly with Thales Alenia
Space, Astrium is developing a common plat-form, known as the Alphabus. It will be a 8-metric-ton bird with very high power require-ments. Greater power translates into alarger footprint across the Earth’s service,enabling operators to reach more end-usersand increase revenues from space-basedservices.
Astrium likes to emphasize the “daily-lifebenefits” from the spacecraft that it deliversto its customers. “Space technology is somuch a part of our daily lives,” the companysays, “that we may not even recognize it —present as it is in so many of the activitiesthat we take for granted today.” Watchingsatellite TV, consulting the weather forecast,phoning someone (around the world or downthe street), accessing the Internet, holdingvideo conf-calls, and checking an in-car navi-gation system for routing information: allbenefits to end-users.
Modular batteries for space
Saft’s VES Li-ion space batteries areattracting interest for all these applications— GEOs, MEOs (dozens of Galileo navigationand localization satellites will be flying withina few years), and LEOs, plus others on stilldifferent missions.
Saft’s Li-ion power for space applicationscomes in three cell-types: the VES 140 and180 for GEOs and MEOs, and the VES 100for LEOs, GEOs and MEOs. Medium-prismaticLi-ion batteries are used for LEOs, launchersand space vehicles. All three VES types areused for space vehicles. Saft’s long-termagreement with Astrium, signed in February2006, stems from close cooperation over thelast decade. Together, the partners havequalified a complete product range, success-fully testing the Li-ion technology in orbit.
Saft gets twoU.S. awardsfor top qualityand service
“We are delighted to receive this presti-gious award, which recognizes our constantefforts to raise the bar in customer servicestandards”, said Saft Specialty Battery GroupGeneral Manager Tom Alcide. Each year,DSCR honours defence suppliers for excel-lent performance as measured by theAutomated Best Value System, based on theDLA database.
In October, Saft was also awarded a 4-star Award of Excellence by RaytheonNetwork Centric Systems (NCS). Only twocompanies received the coveted award,which is for product quality and on-time
delivery as well as price and managementresponsiveness. “We are proud to have wona Raytheon award two years in a row”, saidJim Miller, General Manager of Saft's Spaceand Defense Division in Cockeysville(Maryland). “Now that we’ve won the 3-starand 4-star awards, we’ll be aiming for theultimate standard: 5-star performance”. Saft supplies long-life Li-ion batteries for Raytheon’s Improved Target AcquisitionSystem (ITAS) used with TOW missiles.
SAFT INTERNATIONAL PAGE 11
Bachelier points out. Saft’s basic rangecovers at least 80-90% of customer require-ments. The Li-ion cells can be supplied in achoice of 2P, 3P or 4P modules as well asfour battery configurations: 9S, 10S, 11Sand 12S. “Thales Alenia Space is very atten-tive to a successful qualification of Saft’sVES180 cell for space activities as this cellshould improve the massic energy of 20% ofLi-ion batteries in our Spacebus platforms”,says Isabelle Bachelier.
Why Li-ion in space…and where?
Batteries for high-tech space applicationshave a particularly tough life. There’s no“repair service” in orbit if a battery’s perform-ance starts to falter. So manufacturers ofspace-application batteries must deliver addi-tional guarantees of reliability, performanceand durability. A GEO platform, for example,is expected to operate over a lifetime of15 years without any on-site maintenance.Satellites designed for low-Earth and middle-Earth orbits (LEOs and MEOs) must meetsimilar requirements. And sometimes space-craft do not go into Earth orbit at all: TheEuropean Space Agency’s Smart 1, whichflew to the moon before going into orbitaround it, was the first lunar probe to useSaft Li-ion batteries.
Li-ion battery technology shrinks thevolume that the batteries occupy on the satel-lite platform. It also reduces weight, enablingspacecraft operators to increase therevenue-generating payload and lower theoverall launch weight, resulting in lower costsfor lifting a satellite into orbit.
Saft’s VES Li-ion space batteries areattracting interest for all these applications —GEOs, MEOs (dozens of Galileo navigation andlocalization satellites will be flying within a fewyears), and LEOs around the Earth, as well asa variety of other missions.
Modular batteries for space
Saft Li-ion batteries for space applicationscome in three main cell-types: the VES 140and 180 for GEOs and MEOs, and the VES100 for LEOs, GEOs and MEOs. Medium-prismatic Li-ion batteries are used for LEOs,launchers and space vehicles. All three VEStypes are used for space vehicles.
With Saft’s modular approach, everyonewins: satellite operators and spacecraftmanufacturers as well as end-users hookedup to their “dish” for services from spaceinfrastructure in telecoms, broadcast andother applications. With Saft’s space Li-iontechnology, capacity and footprint grow whilecosts shrink. Now that really is win-win!
Thales Alenia Space is one of the world’sleading space telecom players, with ordersfrom Europe, the United States, Russia,Latin America, Africa and the Middle East,and growing business with Asian customers,especially from China.
Ranked N°1 in the world in 2006 interms of satellites ordered with 30% marketshare, Thales Alenia Space offers anextended platform range, from small topowerful satellites – up to 6,000 kg, with16 kW end-of-life power – featuring greateroperational flexibility, proven reliability andextended life. The current line of Spacebusgeostationary telecom satellite platforms isthe culmination of over 20 years of contin-uous development and now features in-flightproven avionics 4000. This feature is ideal for such applications astelecommunications (including voice, dataand Internet services) and broadcasting aswell as HTDV and mobile TV and 61Spacebus satellites have been alreadyordered.
“We are very pleased with the capabilitiesthat Saft’s Li-ion battery range gives us atThales Alenia Space in terms of customizedsolutions for our customers,” says IsabelleBachelier, Battery Commodity Leader,Purchasing Directorate, based at the ThalesAlenia Space facility in Cannes, France.
Thales Alenia Space manufacturing opera-tions cover four European countries,reflecting the broad geographical presence ofthe company’s high-tech parents. ThalesAlenia Space, which employs 7,200 peopleworldwide, is Europe’s largest supplier ofspace-based infrastructure. “We have imple-mented with Saft a generic Li-ion batteryrange approach which allows us to capitalizemore efficiently on our in-orbit heritage forour customers future programmes,” Isabelle
PAGE 10 SAFT INTERNATIONAL
PARTNERSHIP
Spacebus familyrelies on robust Li-ionbattery range
[email protected] [email protected]
The core Spacebus satellite platforms developed by Thales Alenia Space for a varietyof applications now benefit from Saft’s lithium-ion (Li-ion) batteries. These batteriesare designed specifically for the different platforms’ capacities and requirements.
The U.S. Defense Supply Center Richmond(DSCR), has honoured Saft with its Silver BestValue Medallist award for exceptional productquality and delivery performance. The award wasmade in early June this year by DSCR, the avia-tion supply and demand supply manager for theDefense Logistics Agency (DLA).
TECHNOLOGIES
SAFT INTERNATIONAL PAGE 13
Oil subsea systems rely
on Saft Li-ion technology
Saft has joined forces with FMCTechnologies, a leading supplier of subseaproduction equipment, to increase theadvantages of electric technology overconventional electro-hydraulic and ROV-oper-ated well-control systems. In the first proto-type stage, six Saft rechargeable Li-ionbattery modules will power electrically oper-ated valves controlling production flow onStatoil’s Norne oil and gas field 350 metresbelow the North Sea.
Low-power electric subsea controlsystems using local power storage viarechargeable batteries, already proven onStatoil’s Statfjord field, provide a safer oper-ating environment and prevent corrosionfrom stray high-voltage currents. They alsoreduce costs (topside power generation,transformers, power cables, umbilicals,etc.). But Saft and FMC felt that using Li-iontechnology would make the systems evenmore efficient.
The advantages of Li-ion technology
“The recent development work with Safthas shown that Li-ion battery technology willoffer significant benefits in operationalperformance by enabling us to store muchmore energy within a compact, lightweightpackage with high-cycling capacity than withtraditional cells”, says Vidar Sten Halvorsenof FMC Technologies.
Li-ion technology also makes it easier tomonitor battery cells’ state of charge andstate of health. Remote monitoring andcontrol will be even more vital as the oilindustry works at increasing depth.
And the environment? Saft Li-ion cells arehermetically sealed and maintenance free,ensuring that no gas can escape into thelocal environment.
Purpose-designed batteries
The battery modules developed by Saft in conjunctionwith FMC Technologies comprise seven VL41M cells inseries (nominal 24 V and 800 Wh), housed in a robustnitrogen-filled enclosure designed to withstand extremewater pressures. The modules will be maintained on a floatcharge from the subsea tree’s local 24 V DC supply andwill deliver up to 120 A for the high-torque motors thatoperate the control valves.
separator. At battery level, safety is furtherextended with protection circuits.
Applications where the MP has found anatural “home” include not just portableradars, as in the BEL example, but also inmilitary radio communications, ruggedizedhandheld terminals, transportable medicalequipment, and other civil applications.
PAGE 12 SAFT INTERNATIONAL
Quality for India’sdefence radars
BEL (as Bharat Electronics Ltd is knownlocally) is a pioneer in India’s design andmanufacture of BattleField SurveillanceRadar. It installs Saft’s lithium-ion batteriesbuilt from MP (or medium prismatic) cells inits portable surveillance and acquisitionradar. The radar can be carried in just threepacks for deployment by the Indian army inany location.
The BFSR-SR radar is a Battle FieldSurveillance Radar – Short Range. Itfeatures light weight, man portable andround-the-clock operation in all weatherconditions. It can see out as far as 18 kmand can track 50 targets, including pedes-trians, vehicles, tanks and still more. The resulting colour images are displayed inhigh resolution on a portable PC screen.The radar’s two Saft Li-ion batteries deliver24 volts each.
Created to meet the growing needs ofIndian defence services for electronicsystems, BEL employs the best engineeringtalent available in the country. It manufac-tures state-of-the-art products in suchdefence electronics applications as communi-cations and radar, to mention only two.
World-class standards
The technical specifications (known asJoint Services Specification, or “JSS”) of theIndian army are the most stringent in thedefence industry worldwide. And BEL meetsthem.
For Saft’s part, its Li-ion MP family servesa variety of needs in military and civilian appli-cations. Prismatic cells are flat, rather thanround, potentially enabling more energy tobe captured in a smaller space than what
cylindrical cells can achieve.BEL chose Saft’s MP on the grounds of
reliability and ability to work in the tempera-ture range of -20° to +55°C. One otherimportant decision factor was the engi-neering support Saft provided in developingthe battery with the Indian engineers.
With Saft’s MP cells, both battery andsystem integration improve. On the safetyside, each Saft MP cell features a circuit-breaker, a safety vent and a shut-down effect
Saft Li-ion batteries helpimprove subsea oil and gasproduction controltechnology.Electric subsea technologybased on Li-ion technologyhas major operational andenvironmental advantagesover conventional controlsystems, and specially-designed Saft batterymodules have been helpingNorway’s FMC Technologiesdemonstrate this to the oilindustry out in the North Sea.
FMC Technologies
Bharat Electronics, a half-century-old company based in India, is a supplier tothe Indian defence forces. For its portable electronics, it has selected Saft’shigh-quality batteries, both nickel-cadmium and lithium.
INNOVATION
With rechargeable Li-ion battery systemsestablished in the telecoms industry as apreferred solution to beat the tough condi-tions in outdoor cabinets, Saft has nowlaunched its 2nd-generation Intensium 1Power Plus battery, offering 30% more powerand double the service life.
Compact, zero-maintenancepower
Since Saft launched its Intensium 1 Powerrange of Li-ion batteries, a number ofnetwork operators and OEMs have chosenSaft Li-ion batteries to deliver reliable back-uppower over a long service life, especiallyunder the rigorous conditions involved in
outdoor cabinet applications. Intensium wasengineered to provide exceptional power andenergy density in a compact, zero-maintenance,rack-mounted modular system. Particularemphasis was placed on the needs of fast-growing wireless networks.
Three of the top five telecom OEMs haveselected Intensium systems to equip newcompact micro or macro Base TransceiverStations (BTS) used in GSM or UMTSnetworks. These BTS will be deployed in ruraland highway sites as well as urban sites withdifficult access. The units need up to 3 kW ofpower for short duration back-up to ensurecontinuity of service in case of AC supply failure.This gives the BTS time to either bridge toreserve generation or go to clean standby
mode.
To the next level:Intensium 1 Power Plus
Saft’s new Intensium 1 Power Plus solutiontakes Li-ion telecom batteries to the nextlevel by doubling service life to an anticipated20 years at 20°C and 10 years at 40°C.The new batteries also offer 30% morepower (max. power up from 3 kW to 4 kW),and the standard 48 V system has beencomplemented by a 24 V version.
Saft is also upgrading its manufacturingplant in Poitiers, France, including new dedicated assembly equipment to ramp upproduction to meet expected demandgrowth.
Saft back-up power forTelefonica’s broadband servicesin Spain
As the leading operator in the Spanish-and Portuguese-speaking world, Telefonicaneeds to deliver reliable quality. So thecompany specified Saft NCX rechargeable Ni-Cd batteries for the outdoor cabinets thatare a vital link in Spain’s fast-growing ADSLand VDSL network. Saft’s 48V batterysystems provide up to 4 hours of back-uppower, ensuring continuity of broadbandservice if the main power supply goes down.
The batteries power cabinets in some ofthe hottest parts of Spain, so Telefonica
PAGE 14 SAFT INTERNATIONAL
Saft’s double-play for the telecoms industry
As more countries deploy or extend ADSLand VDSL networks there is growing demandfor batteries that meet the demandingrequirements of outdoor and remotetelecom facilities: reliable power back-up overa long service life in often extreme condi-tions. Saft has now built on the success ofits NCX rechargeable Ni-Cd battery systemsby developing the even longer-life Tel.X solution.
New Tel.X range: long, reliableservice under tough conditions
Saft’s new Tel.X battery is the first highvolumic energy density, long-life, mainte-nance-free Ni-Cd battery specifically designedfor the remote and outdoor equipment thatplays an increasingly important role in
today’s decentralized telecom networks.Tel.X will provide vital back-up power for cabi-nets and end terminals in fibre-optic triple-play networks as well as base transceiversand station controllers in wireless networks.
Due to be available by the 2nd half of2008, Tel.X delivers predictable performanceover a wide -20°C to +50°C temperaturerange and can withstand extremes from -50°C to +70°C. This is vital in cabinetswithout temperature control.
A win-win solution
Other key features are: - Exceptionally long service life (over 20 yearsat normal temperatures and more than 14 years at 40°C)- Maintenance-free under normal operatingconditions (no water top-up)- High reliability- High volumic density of up to 100 Wh/Lwith weight 30% less than a lead-acidbattery- Format designed for standard 19” and 23” racks and cabinets (easy replacement oflead-acid batteries) and compatible with alltelecoms rectifiers- Optimum TCO- Capacity range: 80 to 180 Ah
Rechargeable Ni-Cd solutions for broadband and triple-play
With telecoms rapidly adopting new battery technologies, Saft offers arange of rechargeable batteries developed to meet the specific needs ofoutdoor and remote network plant. These Li-ion and Ni-Cd solutions,providing the power or energy in a much smaller and lighter format, areideal for networks in hot zones where cabinets can reach temperaturesthat make lead-acid batteries age rapidly, resulting in low reliability andpremature failure.
specified not only low maintenance but long,predictable service life in a demanding envi-ronment (summer temperatures inside thecabinets can reach 60°C). Even under thoseconditions, Saft NCX batteries have a lifetimeof more than 10 years, offering Telefonicaoptimum TCO.
Saft is now building on its telecomssuccess by launching 2nd-generation Li-ion batteries and anew Ni-Cd range, offering operatorsand OEMs even more powerful andlonger-life solutions that enhanceTotal Cost of Ownership (TCO).
Intensium 1 Power Plus: 2nd generation Li-ion technology offering more to wireless and wireline networks
[email protected] [email protected]
SAFT INTERNATIONAL PAGE 15
SAFT INTERNATIONAL PAGE 17
Battery lifemodelling
During 2007, Saft will be supplyingmore than a million primary lithium cells topower Hydrometer’s high-tech automatedmeter reading Hydro-Radio modules andSharky BR773 heat meters. The Saft cellswill provide the AMRs with a reliable,maintenance-free “fit and forget” source ofautonomous power over a 12-year servicelife. Hydrometer has ordered a million AA-size LS14500 cells with a nominal2.45 Ah capacity, as well as a smallernumber of A-size LS17500 and C-size LS26500 cells.
Convenient drive-by meter reading
The Hydrometer AMR modules can beused for the latest drive-by meter-readingtechniques. The modules provide a short-range radio link that enables electricity,gas, water and heat meters – such asHydrometer’s well-known Sharky range –to be read, billed and monitored withmaximum accuracy, minimum effort andwithout access to the premises. AMRmodules are usually read by hand-held
PAGE 16 SAFT INTERNATIONAL
MARKETS
Austrian bicycle manufacturer KTM has now decided thatthe time and the technology are right to re-enter the e-bikemarket. Its sporty new machine relies on Saft’s Ni-MHSmart Mobility batteries.
KTM’s new e-bike, which was unveiled atthe Eurobike and IFMA trade fairs inSeptember 2007, is driven by a powerfulHeinzmann motor coupled to Saft’srechargeable Ni-MH 36 V, 9 Ah SmartMobility batteries. The initial production runof 1,000 will be marketed in Austria andGermany.
“The bike is aimed at over-50s (it has notop tube, so it’s easy to mount) and youngerbikers as well (it’s a powerful machine with asporty design)”, says Development ManagerThorsten Cornils. “During customer tests, it recorded between-charge distances of 40-50 km under e-power, depending on usemode”. “The battery can be removed andtaken up to an apartment for charging, sousers don’t need a garage. And the carrieris designed to take a second battery forbikers who want greater range”, he adds.
Three-way cooperation
KTM specified robust batteries (to with-stand jolts and vibration) with high capacity(9 Ah modules), very low impedance (forbetter performance with relatively highcurrent) and the ability to communicate withthe bike (a “fuel gauge” on the handlebarsreceives digital data from the battery bus).
“Our motorization partner, Heinzmann,who is also a Saft customer, assured us thatSaft had the top technological expertise thatwe wanted”, says Thorsten Cornils. “Weworked closely with both companies to deter-mine just the right battery parameters andto optimise communication between compo-nents. This three-way cooperation has beeninvaluable. We are very happy with theresult”.
KTM, based in Mattighofen, near Salzburg, made its reputation withmotorcycles but since the 1960s the firm has also been making a broad range ofbicycles. The fast-expanding company specializes in high-spec, high-quality machines,producing more than 150,000 bikes a year for customers throughout Europe.
[email protected] [email protected]
terminals, but the latest trend is towards“drive-by” reading, where the data isreceived by a GPRS mobile receiver in apassing vehicle.
High performance, long life
Metering is a very demanding applica-tion and Hydrometer specified cells withhigh reliability and reproducible perform-ance. For the AA size, a base current of afew micro-amps was required with pulsesof about 10 milliamps for a few secondsand a cut-off voltage of 2.5V. Saft’sanalysis showed that its LS series Li-SOCl2cells would satisfy performance specifica-tions while easily exceeding the required12-year service life, even with an extremetemperature range. The cells are suppliedwith tabs for easy integration intoHydrometer electronic boards. They willbe fitted to AMRs for utility end-users allover the world.
In order to match metering applicationrequirements more closely, the SaftGroup has now developed a uniquemodel – based on field and lab datacollected over 30 years – to predictprimary lithium battery service life forspecific utilization profiles. Resultsfrom the model, which factors in basecurrent, pulse currents, cut-offvoltage and temperature range, arecombined with bench-test results togive an accurate life prediction.
The Saft Group is the world’s leading manufacturer of batteries for meters andAMRs.
Smart Mobility
It comes in a robust aluminium casing for “rough” biking, and in addition tocharge/discharge management it has a memory unit that records the battery’sworking life (charged/discharge history, current rate, operating temperature,storage periods…) to help optimise battery use. This unit allowed Saft to propose anextended 2-year (or 500-cycle) warranty, as it is possible to track the real use of thebattery. It will also be very helpful in handling after-sales queries. And because thebattery “knows” when it has been stored for winter, it will modulate the first spring-time charge accordingly.
Another key feature of this new battery design is the ability to replace the internalcore pack while keeping the same casing and electronics. This lowers the cost ofreplacement and therefore the overall life-cycle cost.
The new-generation Smart Mobility battery is a development of Saft’searlier plug-and-play solution supplied in 12, 24 and 36-V modules.
KTM re-enters the e-bike marketwith a new City Bike concept
powered by Ni-MH Smart Mobility technology
Hydrometer, a leading manufacturer ofautomated meter reading (AMR) devices,has turned to Saft primary lithium batteriesfor reliable, maintenance-free and long-lifeoperation. Saft will be providing a millionAA-size LS14500 cells. The batteries willpower the latest time- and labour-savingdrive-by meter reading technique.
Long-life “fit and forget”primary lithium for
radio-linkautomated meter-readers
EXTREME POWER
Saft rechargeable Ni-Cdbatteries were installed inthe Pack tunnel in 1982and are still performing wellnearly 25 years on. Today, Saft batteries provideemergency back-up power inwell over 50 road tunnels inAustria.
Saft’s Ni-Cd batteries are designed toprovide up to two hours of emergency back-up power in the event of a mains powerfailure (for safety-lighting, signaling andcommunication systems, fire alarms, emer-gency doors, exhaust air valves, etc.). Theoperator of the Pack tunnel, ASFINAG, wasso delighted with Saft performance that in2004 it naturally turned to Saft again forback-up batteries for the new, second tubeof the 10-km Plabutsch tunnel.
Performance even better thanexpected
An ASFINAG’s spokesman explains: “Inthe late 1970s, when we were first consid-ering battery options for the Pack tunnel, weestablished a minimum 10-year service lifeas one of the key criteria. In view of thedemanding conditions, we believed this to bea very optimistic goal, especially for lead-acidbatteries. However, when the LCC (Life CycleCosting) analysis provided by Saft’s agentStatron showed that we could expect 20-yearplus service life from Ni-Cd batteries, theybecame the obvious choice. There were ofcourse other important factors such as:ease of maintenance; a wide range of oper-ating temperatures; the capability to with-stand the environmental conditions in thebattery room; and a predictable service lifewith no risk of sudden-death failure”.
Nearly 25 years down the track, the orig-inal Saft batteries are still functioning well, atabout 70-80 % of nominal capacity. SoASFINAG naturally chose the same type of
batteries for all the other tunnels in thesection, including Plabutsch, which isEurope’s longest double-tube road tunnel.
a group effort to get Li-ion batteries aboardtheir GEO-Mobile satellites”, says Saft CEOJohn Searle. “Li-ion technology, with its supe-rior performance and reduced bulk andweight, is the ideal battery solution for spaceapplications”. This partnership with Boeingadds to Saft’s impressive list of spacecraftprogrammes and strengthens Saft’s positionas a leading supplier of Li-ion batterysystems for the U.S. space market.
PAGE 18 SAFT INTERNATIONAL
The two GEO-Mobile satellites, among thelargest and most powerful ever built, will bepart of an advanced commercial telecommu-nications network. Saft’s VES140 40-Ahrechargeable Li-ion cells (in a 6P12S configu-ration) will power critical systems, ensuringcontinuous operation of the satellites whiletheir solar panels are in eclipse. And they willdo it for up to 18 years.
Win-win power/weight ratio
Saft’s win-win solution provides highspecific energy of 120 Wh/kg in a light andcompact format, offering a very significantweight advantage (30-50%) over the previously used Ni-H2 battery chemistry andallows Boeing and MSV to dedicate more ofthe satellite’s crucial mass to revenue-gener-ating payload. This is a big plus as the voiceand data satellites are required to supply
11,000 watts of power.Boeing’s GEO-Mobile
satellites, based on thecompany’s powerful 702 infrastructure, willbe part of the world’sfirst commercial mobilesatellite service usingboth space and ground-based elements. The telecommunications network, based onMSV’s patented Ancillary TerrestrialComponent (ATC) technology, combines thebest of satellite and cellular technology toensure reliable and widespread delivery ofadvanced voice and data.
Ideal technology for spaceapplications
“Saft has been working with Boeing formany years and this contract is the result of
franç[email protected]
SAFT INTERNATIONAL PAGE 19
Boeing MSV satellites:Li-ion power for greater payload High-energy, low-weight Saft Li-ionbatteries have been selected by Boeing topower two GEO-Mobile satellites for theMobile Satellite Ventures telecommunica -tions network. This multi-million dollardeal is Saft’s largest U.S. commercialsatellite contract for Li-ion batteriesand its first with Boeing.
25 years of Ni-Cdemergency back-up power
in tough tunnelenvironments
Ni-Cd tunnelbatterysystemsTypically, up to nine Saft battery systemsare installed in each tunnel, each systemcomprising hundreds of SBM and SBL Ni-Cd batteries with capacities rangingfrom 68 to 690 Ah. These are blockdesign batteries with robust pocket-plateconstruction and developed specifically todeliver reliability, long service-life and lowmaintenance.
Saft Ni-Cd batteries, a hospital can takeadvantage of opportunity charging to maxi-mize AGV availability (at least 22 hours a day)and reduce the number of AGVs it requires.
Density, power and low maintenance
Battery discharge rate naturally dependson the load carried and the distance travelledby the AGV. To ensure maximum availability,Swisslog aims to maintain the batterysystem at 50-80% state of charge, which isachieved by opportunity charging, even forshort down-time periods. A 100-A sourcecan charge about a third of the STM modulecapacity in under 20 minutes.
Saft STM modules have been developedspecifically to meet the needs of electric vehi-cles: energy density (for range), power (foracceleration) and low maintenance (forreduced operating costs). Each TransCarAGV is equipped with 4 Saft STM 5-100modules in series to create a 24 V, 100 Ah battery system. The batteriesfeature sintered positive electrodes andplastic-bonded negative electrodes.
PAGE 20 SAFT INTERNATIONAL
EVOLVING PLANET
Swisslog, the international manufacturerof turnkey logistics systems and containertransportation systems for hospitals,recently switched to Saft’s rechargeable Ni-Cd battery modules for its new-generationTelelift TransCar LTC2 automated guidedvehicles (AGVs). The fast charging and deepcycling capability of the Saft STM modulesenables Transcar users to take advantage ofan “opportunity charging” system, givinground-the clock operation that would not bepossible with lead-acid batteries. Whenever
the system control centre (which also moni-tors battery levels) determines that the AGVwill have down time, even just a few minutes,it can route the vehicle to a charging station.
State-of-the-art AGVs
AGVs like the Swisslog system aredesigned to transport a variety of items(refuse, clean and soiled linen, medicalsupplies, patient meals) through a hospitalsafely, accurately and continuously, deliveringand retrieving 4-wheel carts of varyingconfigurations and loads. The latestTransCar is based on compact, low-profile,bi-directional vehicles using a contour-following laser guidance system. The easily-expandable system requires no wall targets,embedded wires, floor tape or other buildingmodifications.
The Saft Ni-Cd batteries in the TransCarprovide power for traction and the guidancesystem as well as for the 450-kilo capacitylifting platform that raises the hospital cartsoff the floor.
The advantages of Ni-Cd technology
In this application, Saft Ni-Cd moduleshave a clear advantage over lead-acidbatteries, which cannot be fast charged andwould have to be replaced by freshly-chargedbatteries every 8 hours. This involves addi-tional costs: spare batteries, labour tochange them and longer AGV down time. Byusing Swisslog AGVs powered by deep-cycling
SAFT INTERNATIONAL PAGE 21
To cope with growingdemand for “everywhereInternet”, Sweden’s telecomsincumbent Telia Sonera hascome up with a novel solu-tion. They are equippingphone booths all over thecountry with broadbandWiFi modems – powered bySaft Ni-MH SmartModules.
Telia Sonera’s idea is quite simple: determinewhich existing phone booths are in or adja-cent to sites where people could sit and surfor chat with a laptop (parks, town squares,shopping centres, university campuses, etc.)and then equip those booths with WiFidevices (modem, antenna, etc.). “This typeof WLAN in public areas is a new develop-ment”, says the project’s Technical ManagerStig Olausson. “Tests have been done in theUK and Germany but this is the first large-scale implementation”.
Internet in the park...
The only problem was… power. Unlikefixed line phones, modems need an externalpower source. Rather than building a grid forthe booths, Telia Sonera is powering thedevices with batteries that are recharged atnight via a cable to the nearest streetlight.Pretty nifty…Starting in summer 2007, the first hot-spotbooths are being set up in Stockholm,Göteborg and Malmö, and additional Wi-Fibooths will later be installed in 20 othercities. To power the first batch of 550booths, Saft (through its local distributorCelltech) is supplying 725 12-V SmartModules (400 in 14.5 Ah and 325 in 9 Ah).
Telia Sonera needed high-capacity
batteries (the modem draws 0.5 A continu-ously) “They must also charge/discharge attemperatures from -40°C to +40°C (ourwinters can be really cold and summer veryhot). And batteries used in the north mustbe able to charge quickly because duringshort summer nights streetlight current isavailable for a very limited period”, adds StigOlausson. In these cases, two smallerbatteries will be used for faster simultaneouscharging. Saft’s Smart Modules not onlycontrol charge/discharge but communicatewith computers in the Stockholm controlcentre so that cycling and condition ofbatteries in remote regions can be moni-tored in real time.
Lower costs forHouston hospital
The 485-bed Memorial Hermann
Southwest Hospital in Houston, Texas
recently switched from a 26-year old wire-
guided AGV to Swisslog’s Transcar system
with Saft Ni-Cd. Increased availability
thanks to opportunity charging means
that the hospital now gets more work out
of just 16 vehicles than it did with its old
fleet of 60-plus units, whose carts also
had to be manually loaded. Hospital
management estimates savings at more
than €8.5 million over 15 years.
Telia Sonera is the leading telecommunications company in theNordic and Baltic region, with strong positions within mobile communications in Eurasia,Turkey and Russia. At the end of 2006, Telia Sonera launched mobile services in Spain.The company provides reliable, innovative and easy-to-use services for transferring andpackaging voice, images, data, information, transactions and entertainment.
Smart Ni-MH powerfor Sweden’s innovativehot-spot phone booths
Internet surfing in public areas is nowpossible thanks to Telia Sonera
Fast-charging Ni-Cd batteries helphospitals boost AGV efficiency and save moneySwitching to Swisslog TransCar Automated GuidedVehicles (AGVs) powered by Saft rechargeable Ni-CdSTM battery modules can enable hospitals to takeadvantage of “opportunity charging” to boostinternal transport efficiency and reduce thenumber of AGVs required.
SAFT INTERNATIONAL PAGE 23
For nearly three years now,the ten households onNorway’s Utsira Island havebeen powered by wind energycoupled with hydrogenstorage, with buffer powersupport from Saft Ni-Cdbatteries. This award-winning pilot scheme, aworld first, is helping openthe way for renewables.
The small community on their remote off-grid island gets all its electricity from renew-able sources, and Saft batteries providebuffer power support to ensure completesystem reliability. The Utsira project, jointlydeveloped by the Norwegian energy groupStatoilHydro and ENERCON, is the world’sfirst practical demonstration of how windpower and hydrogen storage can worktogether to provide an efficient and reliablestand-alone energy supply. The project,which won the 2004 Platts Global EnergyAward for the best renewable energyproject, is due to run until autumn 2008.
Wind turbines + hydrogenstorage + battery buffer
With only 220 inhabitants, the rockywindswept island off Norway’s west coasthas modest power requirements, and peakload of 900 kW can usually be met by windpower. During windy days, the two 600-kWEnercon wind turbines generate more elec-tricity than the islanders need, soStatoilHydro developed a way to store part ofthat energy in the form of hydrogenproduced by water electrolysis. Ten house-holds with a peak power of 55 kW are
connected to the stand alone system. Whenthe wind dies, a hydrogen motor and fuel cellconvert the hydrogen back into electricity. Toensure stability of the island grid, short-termstorage for smoothing of wind energy (in theseconds range) is handled by a 200-kWEnercon flywheel, and for longer support (upto 30 minutes) the batteries cut in. The 37-kWh Saft battery system, a vital buffer inthe island’s energy chain, ensures completegrid reliability in the event of heavy load varia-tions, component failure and bridgingbetween generation methods.
The main criteria for the batteries were
cycle life and robustness rather than energydensity. After intensive tests, Saft Ni-Cdbatteries with their high-cycling capability inhigh-rate applications were selected as theoptimum combination of cost, reliability andperformance. The battery system (140 Ni-Cdcells in series with a nominal voltage of 168 V and power capacity of 40 kW) is kepton a float charge and is typically called on fora few minutes support once a day.
Electricity for off-grid communities,thanks to an innovative wind power-hydrogen storage system
PAGE 22 SAFT INTERNATIONAL
EVOLVING PLANET
Saft’s rechargeable Ni-Cd batteries are taking to thewater, providing efficient and environment-friendlypower for two new all-electric water buses thatstarted operation in October 2007 on the Saint-DenisCanal in Paris. An innovative project that wasmade feasible by Saft’s low weight, high-powerbattery solution.
The new water buses provide a shuttleservice for employees of the real-estategroup ICADE commuting to the company’sMillénaire Park offices in the 19tharrondissement of Paris. The serviceconnects the Corentin-Cariou metro stationto the dock at Millénaire Park, a trip of about7 minutes, and then continues on to the“Portes de Paris” Park just outside the citylimits.
The catamaran-type boats, La Montjoieand L’Estrée, each equipped with 2 steerableelectric motors, can carry up to 75 passen-gers at speeds of 6-12 km/h over the 1.1 kmroute (top speed is 16 km/h). The highenergy storage capacity and light weight ofthe Saft rechargeable Ni-Cd batteries enablethe water buses to operate for about 6 hours(30 round trips) between charges.
Battery weight: the key tosuccess
The water buses were designed and builtby Alternative Energies. Contractor EVESystem focused on the on-board energystorage management, working in close part-nership with Saft’s technical teams to designthe integrated Ni-Cd battery system. At2,150 kg, the system is about 30% lighterthan lead-acid batteries with equivalentpower, and without this weight saving a 75-passenger electric boat would not havebeen feasible.
The boats’ battery systems are based onSaft’s STM modules, specifically developedfor all-electric propulsion applications andfeaturing light weight, high energy density(for range), high power (for acceleration) and
low maintenance (for economical operation)combined with fast-charging and deep-cycling capability.
The propulsion battery systemcomprises two strings of 64 STM 5-140modules connected in parallel, providing anominal 400 V and 110 kWh capacity. Safthas also supplied smaller STM-basedsystems providing back-up power for theboats’ radios and other electronic devices.
Optimum operational availability
The deep-cycling capability of Saft’s STMmodules enables the boats to operate for a6-hour shift on a single, full overnightcharge. Unlike lead-acid batteries, thesystem can be fast-charged, so a shortcharging break is enough to let the boatsoperate for a further 3 hours. This featurealso means that the operator can take fulladvantage of “opportunity charging” if theboat stays at the dock for longer thannormal, such as outside peak travel times.
Environment-friendlyurban transport Compared to Paris buses and the other canal boats in the city, these all-electric“canal cats” require less than a third as much energy per passenger. And just toreinforce the environment-friendly nature of the project, battery power can becomplemented (weather permitting) via solar PV panels on the cabin roof that cansupply more than 10% of the energy required.
All-electric energy-savingcanal boats for Paris
…and outsourced maintenance
To enhance project economics, ICADEleases the battery systems on a ‘full-service’basis from Sodretel, which has responsibilityfor maintenance and servicing of the batteriesover a 5-year period. This subsidiary ofFrance’s power utility EDF worked with EVESystem to ensure that maintenance operationswould be simple and cost effective.
Ni-MH technology, which has a power-to-weight advantage over SLA. Flo Healthcarehad not yet come up with a workable solutionto its particular needs. “A reliable powersource is vital to critical health applications,but above all the cart’s IT equipment andrechargeable power source must workperfectly together”, says Flo Healthcare’sSystems Engineer Karl Haiden.
“Saft had a reputation for cutting-edgeexpertise, so we asked its technical team tocome and look at the power and chargingsolutions we were trying to use”, adds Karl.“They were very responsive and quick torecognize how our product’s system could beimproved. Saft suggested using its VH D9500 packs in parallel and offered to sharethe concept of its proprietary charge algo-rithms, enabling us to overcome a parallelcharging technical issue. Saft’s technicalexperts helped us create a mobile wirelessworkstation that offers longer runtimes,lighter weight, and faster charge times thanits previous version”.
Multiple advantages
The use of high energy-density Ni-MHpacks reduces the overall cart weight by33% compared to SLA and also greatlyincreases the number of charge-dischargecycles. The ability to parallel charge thepacks increases cart runtime. The cart’smicrocontroller-based system allows Flo Healthcare to offer hospitals scalablepower: units can be customized using 4 to6 packs in parallel (the usual option is 4) to increase deliverable runtime on demand.
Mobile workstations are used in mostmodern hospitals to collect data and keepthe caregivers right up-to-date on patientcondition and treatment. Units like FloHealthcare’s latest model are fully inte-grated, ergonomic mobile workstations thatare designed to be the most versatilehospital computer cart available.
Better health care
These mobile workstations are able to gowhere nurses need them most – right to thepoint of care. The workstations allow wire-less transmission of patient data to thehospital’s clinical information system, thusmaking data available in real time to all relevant medical personnel. Larger hospitalsdeploy several hundred carts equipped toinput a variety of data.
Atlanta-based Flo Healthcare, a marketleader, builds the carts and integrates ITequipment that is customized to the systemneeds of each hospital. The carts come fullyassembled and ready to roll “right out of thebox”. The wireless mobile workstations arepowered by 4 to 6 Saft 12-cell Ni-MH VH D9500 packs delivering 9,500 mAh at14.4 V each. Flo Healthcare’s main marketis in North America with expansion focusedon export sales, particularly in Europe.
Charging algorithms matched tothe batteries
For many years Flo Healthcare, like itscompetitors, used sealed lead-acid (SLA)batteries but recently decided to switch to
Innovation as differentiator
Flo Healthcare’s new workstation ispreferred by most nursing staffs for itsergonomics, esthetics and ease of use.Hospital IT professionals appreciate how Flodelivers reliable, integrated ready-to-use solutions with a choice of technologies. “Themove to Ni-MH was a differentiator for usand Saft helped us achieve it”, adds GeneralManager Keith Washington. “Saft showed ithas the expertise and the willingness to solveexisting and future technical challenges weencounter. That’s very reassuring for acompany like ours that uses innovation as amarket differentiator”.
[email protected]@saftbatteries.com
Medical workstation manufacturer Flo Healthcarerecently teamed up with Saft on a new solutionusing Ni-MH packs charged in parallel, significantlyincreasing the runtime of its next-generation mobilewireless workstations.
Saft is supplying speciallydesigned Li-ion batteries for aninternational Boeing-led projectto develop environmentallyprogressive technologies foraerospace applications.
Boeing Research and Technology Europe(BR&TE), together with selected partners inSpain, Austria, France, Germany, the UnitedKingdom and the United States, has devel-oped a manned single-seat propeller-drivenaircraft powered only by a fuel cell and light-weight Li-ion batteries. Saft was chosen todesign and assemble both the auxiliarybatteries and the back-up battery. Theproject has been under way since 2003. The systems integration has been completedand ground tests are due to start thisautumn in preparation for the flight tests.
“Given the efficiency and environmentalbenefits of emerging fuel-cell technology,Boeing wants to be at the forefront of devel-oping and applying it to aerospace products”,says BR&TE managing director FranciscoEscarti. This project is an important step inthat direction for all companies taking part,including Saft.
The demonstrator aircraft uses a ProtonExchange Membrane (PEM) fuel cell +lithium-ion battery hybrid system to power anelectric motor, which is coupled to a conven-tional propeller. The fuel cell provides all
power needed for the cruise phase of flightbut during take-off and climb, when mostpower is required, the system draws on SaftLi-ion batteries 237V 20 Ah (66S 1PVL20P) batteries.
The hybrid aircraft, with a wingspan of16.3 metres (53.5 feet) and a cruisingspeed of 100 kph (62 mph) will pave the wayfor using this technology in small mannedand unmanned aircraft.
With its next-generation technology, theArmy’s manned ground vehicles (MGVs) willachieve their aim of being easily trans-portable, deployable, lethal and survivable.Saft’s very high-power Li-ion modules play acritical role in acheving this.
To supply the U.S. Army’s needs, BAESystems has teamed up with GeneralDynamics to develop a family of MGVs forthe FCS Lead System Integrator team ofBoeing and SAIC. All Saft Li-ion batteriesfeature complete electronic controls(CANProbe ™) that provide both safetyfeatures and comprehensive battery status.The cell to be used is part of Saft's VL Vrange, the world's most powerful Li-ion cells,thanks to their superior thermal characteris-tics and very low impedence.
Technology enabler
BAE and General Dynamics are supplyinga family of MGVs. This next generation ofhybrid combat vehicles will provide themajority of firepower in the FCS-equippedbrigade combat teams. They will be criticalnodes in the overall network that enablessoldiers to complete their missions moreeffectively. The Saft lithium-ion batteries areone of the key enablers for the hybrid drivesystem. This hybrid system will allow bothimproved efficiency and silent capabilities,providing the soldier of the future withenhanced capability.
Ni-MH: the “right stuff” forhigh-tech medical workstations
On the hybrid battlefield with Li-ion
Saft Li-ionbatteries help power Boeing’shybrid fuel-cell/electric aircraft
INNOVATION
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BAE Systems is to supplyhybrid vehicles with Saft’slithium-ion (Li-ion)rechargeable batteries forthe U.S. Army.
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During the June 18-24 Paris Air Show, Saft announced that it was cooperatingwith leading European aircraft manufacturers to perfect its leading-edge Li-iontechnology for aviation applications.
Capturing synergies
Saft has been at the forefront of aircraftbattery technology (mainly Ni-Cd electro-chemistry) since 1932 and has morerecently become a leading developer andsupplier of Li-ion battery systems fornumerous applications.
This extensive dual expertise is beingleveraged, together with the experience ofleading aeronautics players, in two researchprogrammes, ELISA and BATTLION, todevelop an innovative Li-ion battery system to meet the requirements of both civil and military aviation applications.
Focusing on integration
The new battery system will be connected tothe DC bus, thanks to an integrated chargecontrol and monitoring system. It featuresboth state-of-health (SOH) and state-of-charge (SOC) indicators and communicateswith an aircraft’s management system. Inaddition to the zero-maintenance advantageand the weight- and size savings brought byLi-ion technology, the new system will reducecosts by integrating the control electronicsand charger inside the battery system box.
Saft was chosen by the transatlanticaerospace systems and equipment manufac-turer GE Aviation (formerly SmithsAerospace) to supply both Li-ion and Ni-Cdbatteries for the Lockheed-Martin F-35Lightning II, which made its flight on15 December 2006 in Fort Worth, Texas.
Saft’s Li-ion 270 V High-Power Batteriesand Ni-Cd 28 V Aircraft Maintenance-FreeBatteries (AMFB) provided essential power
for the JSF’s flight-control surfaces as wellas for start-up, in-flight battery power distri-bution and back-up in the event of mainpower failure.
Saft began work on design, developmentand qualification of these high-reliability
batteries in 2002. This is the first time thata fighter aircraft has used Li-ion technologyin mission-critical applications.
MARKETS
The CITADIS T3 trams, which have beena great success, carry up to 100,000passen gers per day between the Pont duGarigliano and the Porte d’Ivry. All 21 of theT3 tramcars in service are equipped withSaft 19 MRX 260 batteries in integratedtrays. The MRX has a centralized water-filling system that saves time and reducesmaintenance costs. The batteries provideback-up power for emergency lighting, ventila-tion and passenger communication as wellas emergency braking.
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New Paris tram relies on low-maintenance Saft batteriesThe new Alstom T3 tram thatwent into service in December2006 on a stretch of the innerring boulevard around Paris isequipped with Saft Ni-Cd batteriesoptimized for low maintenance.
Saft launches Li-ion aviation batteryprogramme at Paris Air Show
Customized Li-ion and Ni-Cdbatteries onJoint StrikeFighter’s firstflight Show
When a French railwayshigh-speed train (TGV)smashed the worldrailway speed recordon 3 April 2007, thetrain’s manufacturer,Alstom, chose Saftback-up batteries forthe attempt.
The specially modified V150 prototype25,000-hp TGV made up of 2 engines and 3 double-level cars, reached 574.8 km/h(356 mph) on the track between Paris andthe eastern city of Strasbourg.Trains in normal service on the recentlyopened high-speed track will be allowed toreach 320 km/h.The record-breaking train, like all of France’shigh-speed trains, was equipped with Saft Ni-Cd Matrics MRX-type batteries, whichprovided optimum back-up power for theTGV’s auxiliaries and braking.
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Saft back-up power for Alstomrailway speed record
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