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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