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Abstract— This paper presents the results of capacity presented an overly optimistic view of the performance of
discharge tests on approximately 15,000 VRLA cells, of the entire VRLA population. The large proportion of the
primarily AGM design, representing five different US VRLA population, used in outdoor, extreme environments
manufacturers’ “20 YEAR DESIGN LIFE” products. was not represented in these failure rate data. In those
Some data are also presented on gel design cells. Just as environments, lifetimes are significantly shorter, with
was found in the earlier paper, presented at the 1995 failures often of a more dramatic nature, such as thermal
INTELEC meeting, the cells showed significant premature runaway or actual explosion.
capacity loss beyond 2 years’ service in benign,
temperature controlled environments. The cells tested At the time of the 1995 study, several new VRLA products
generally represented designs that were too new to have had just been introduced, either from manufacturers whose
been included in the earlier study. While it had been products had not been in the original test population, or as
hoped that these newer design cells would have been a result of new designs from existing manufacturers.
modified to correct the early failures shown in those tested While those products were too “young” at that time to
in 1995, this was apparently not to be. In accord with that expect to show capacity problems, the hope and
study, as well as an extensive Swedish study of 35,000 expectation was that the manufacturers had long since been
VRLA batteries, presented at the 1995 INTELEC, the most aware of the aging effects shown by the earlier designs and
significant conclusion from all these studies is that current had taken the necessary remedial steps to insure that the
VRLA cells, regardless of manufacturer or design, newly introduced designs would, in fact, show significant
demonstrate acceptable reliability for only 2 years. improvement.
100%
80%
Failure Rate
60%
40%
20%
0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9 7–7.9 8–8.9 9–9.9
Age (years)
80%
70%
60%
Failure Rate
50%
40%
30%
20%
10%
0%
1-2 3 4 5 6 7 9
Age (years)
100%
80%
Failure Rate
60%
40%
20%
0%
0-2 3 4 5 6 7 8 9
Age (years)
1995 1998
Tables 4–8 show the detailed failure rates, for products by speculate that the older population may have been
each of the manufacturers. The same data are shown “ethnically cleansed” of many of the failed cells. In
graphically in Figures 4–7. Of the five manufacturers addition, field repair attempts by water addition have likely
shown, only two had test data included in the 1995 paper. contributed to this improvement as well[14]. In any case,
In that paper, manufacturer A had 15,627 cells within the the failure rates are clearly unacceptable by year 3.
3–7 year age band, with an overall failure rate of 69%. In
this year’s paper, the same manufacturer’s data are shown Table 5 and Figure 5 show the new data for manufacturer
in Table 4 and Figure 4. This shows an overall failure rate D. In the 1995 paper, the 3–7 year data for manufacturer
of only 23%, but the 5,500 cell population is heavily D showed a failure rate of 75% out of an overall population
weighted by minimal failures in the 2,892 cell 1st and 2nd of 288 cells. Table 5 shows an overall failure rate of only
year populations. Removing those years, and comparing 6% in a 2,640 cell population. Again removing the 2,052
on the same 3–7 year basis as in the earlier paper, results 1st to 3rd year cells, results in a population of 588 cells from
in 987 failures in a 2,358 cell population, for a failure rate, 3–6 years old, with 129 failed cells, for a failure rate of
from 3–7 years of 41%. Adding in the 8th and 9th year data 22%. Although this failure rate is significantly lower than
results in an overall population of 2,621 cells, with 1,249 in the previous study, it is still unacceptably high for a
failures, for an overall 3–9 year failure rate of 48%. While product claimed to have a 20 year design life.
this may seem to be a slight improvement, we might
<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 2,264 40 2% 2 0.1% 0 0%
2–2.9 228 3 1% 0 0% 0 0%
3–3.9 840 323 38% 14 2% 1 0.1%
4–4.9 588 151 26% 14 2% 4 1%
5–5.9 324 129 40% 44 14% 15 5%
6–6.9 238 61 26% 32 13% 15 6%
7–7.9 368 323 88% 258 70% 233 63%
8–8.9 167 166 99% 129 77% 105 63%
9–9.9 96 96 100% 96 100% 96 100%
Total 5,513 1,292 23% 589 11% 469 9%
100%
80%
Failure Rate
60%
40%
20%
0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9 7–7.9 8–8.9 9–9.9
Age (years)
80% Failures 60% Failures 50% Failures
80%
60%
Failure Rate
40%
20%
0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9
Age (years)
Table 6 and Figure 6 show results for one of the Table 7 shows another product too new to be included in
manufacturers (here named manufacturer “K”) whose the earlier paper, and here named “L”. In the 477 cell
product was too new to be included in the earlier paper and population, no cell is older than 2 years, so that the zero
which had presumably included material and design failures seem reasonable. For these, we can only say
corrections to the problems shown by the earlier designs. “WAIT ‘TIL NEXT YEAR”!
Here, in a population of almost 2,700 cells, the overall
failure rate was 27%, more or less in qualitative agreement Table 8 and Figure 7 show data from another manufacturer
with both the overall group and manufacturer A’s product. (M) who has been in manufacture for some time, but for
However, closer examination on a yearly basis indicates a whom no discharge test data were available for the earlier
far more serious problem. While year 1 is trouble free, in paper. While the overall population of some 3,000 cells
the 2nd year failures reach 10%, then rapidly climb to seems significant, 2,996 or 98% are in UPS service and
54%, 72% and then 73% in the 3rd, 4th, and 5th year. The 2,276 are less than 3 years old. Only 48 cells are 4 years
sudden drop to zero in year 6 is likely a statistical anomaly, or older. Of these, 7 tested as failures to the 80% criterion,
considering the small sample size. for a 15% failure rate, but the population size is not
statistically significant.
<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 810 0 0% 0 0% 0 0%
2–2.9 830 86 10% 35 4% 5 0.6%
3–3.9 335 181 54% 79 24% 72 21%
4–4.9 598 433 72% 192 32% 131 22%
5–5.9 48 35 73% 26 54% 21 44%
6–6.9 69 0 0% 0 0% 0 0%
Total 2,690 735 27% 332 12% 229 9%
80%
60%
Failure Rate
40%
20%
0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9
Age (years)
20%
16%
Failure Rate
12%
8%
4%
0%
0–1.9 2–2.9 3–3.9 4–4.9 5–5.9 6–6.9
Age (years)
While all of the above data refer to AGM type VRLA cells, size, since the individual populations would have been too
a limited amount of data has been collected on gel type small to have any statistical significance. However, the
VRLA designs. The data, shown in Table 9 and Figure 8, failure rates are similar to those found in an earlier
represent the products of three US manufacturers and publication by two of the authors[10], in which 2-year old
include several different sizes of each. As a result, no gel cells were found to have failed in 11 of 38 6-volt
attempt was made to segregate the data by manufacturer or monoblocs, for a 29% failure rate.
<80% Capacity <60% Capacity <50% Capacity
Age Number Number Percent Number Percent Number Percent
(years) of Cells Failed Failed Failed Failed Failed Failed
0–1.9 16 0 0 0 0% 0 0%
2–2.9 0 0 0 0 0% 0 0%
3–3.9 0 0 0 0 0% 0 0%
4–4.9 96 4 4% 0 0% 0 0%
5–5.9 212 25 12% 8 4% 0 0%
6–6.9 72 24 33% 24 33% 2 3%
7–7.9 120 24 20% 24 20% 24 20%
8–8.9 24 0 0% 0 0% 0 0%
9–9.9 48 0 0% 0 0% 0 0%
10–10.9 72 24 33% 0 0% 0 0%
Total 660 101 15% 56 8% 26 4%
40%
Failure Rate
30%
20%
10%
0%
0–3.9
4–4.9
5–5.9
6–6.9
7–7.9
8–8.9
9–9.9
10–10.9
Age (years)
While there can be some questions raised as to the manufacturing processes and controls to ensure that
statistical significance of some of the aging failures, for reliability.
some individual manufacturers, and especially for the gel
technology, there can be no doubt as to the overall Unfortunately, the above statements represent the “GOOD
message. Despite all claims to the contrary, there is no NEWS”. The “BAD NEWS” is that the largest use of
evidence, either from the 1995 paper or from these data, VRLA products is in outdoor, uncontrolled temperature
that any of these designs will achieve their 20 year design cabinets. Here we have no quantitative test data, primarily
life, even in benign temperature environments. The data since the user has come to expect such a short life in these
strongly indicate that the AGM VRLA 20 year design outdoor environments, that he generally replaces the
life product can only be considered as a reliable 2 year batteries automatically after no more than 2–3 years.
design. Since significant failures begin to occur in the Under these circumstances, the user cannot justify the
third year, any claim to reliability beyond the two year age economics of performing capacity discharge tests. In
has to be contrasted against our long-term experience with addition, in many cases he cannot justify either the use of
flooded cell reliability. That reliability has resulted from ohmic techniques to detect failures, nor in many cases can
our understanding of its failures modes and their he justify the cost of monitors with remote access,
dependence upon the interrelationships among the especially since in their attempts to lower the cost of the
metallurgical, electrochemical, and mechanical field monitors, some manufacturers have produced
interactions that govern flooded cell float behavior and life, products of questionable accuracy in their ability to detect
coupled with the development of the necessary significant cell failure for these outdoor installations.
0 and 5 years. Figure 9 shows their results, taken from
An obvious question which arises, is whether these results Figure 1 of their paper. While the results show some
are a peculiarly US-only phenomenon such that VRLA differences, depending on the overall voltage of the battery
cells made elsewhere are all performing in accordance with plants involved, their results are certainly in close
their expected design lives. As noted earlier, the data agreement with the overall results of both our 1995 study
presented in the 1995 paper included cells made and used and this study. Further, the authors note that because of
in the UK, Europe and in the Pacific Rim countries. Those the frequency of failures, two makes of AGM designs were
data showed the same characteristics as the US cells in the withdrawn from the Swedish market. While this has not
1995 study, as well as those in this study. Further, in a yet been publicly stated in the US, there are statements
paper also presented at the 1995 INTELEC, Selanger and which have been made as to the intentions of some
his co-authors report on a study of the capacity/age/failure telecoms to ban all further purchases of VRLA products,
rates of some 35,000 VRLA cells, in Telecom, Utility and for outdoor applications. For controlled environment use,
Defense usage[15]. In overall summary, they reported that flooded cells of proven reliability are considered a more
failure rates for gel cells are approximately 5% and for desirable option and are increasingly being considered and
AGM approximately 20% for batteries between the ages of selected, where space and use conditions permit.
Defect
Fraction
70%
60%
50%
40% 24 V
48 V
30% 110 V
20%
10%
0%
0 1 2 3 4 5 6
Age (years)
IV. CONCLUSIONS
4. While no quantitative data are available, it is
1. Capacity test data on some 15,000 AGM “20 year acknowledged that in the major Telecom outdoor
Design Life” cells indicate significant and cabinet usage, exposed to high temperature
unacceptable failure rates beyond the second year of environments, VRLA cells are routinely “junked” after
life, under benign environmental conditions. no more than 2–3 years, without further testing, which
has generally been considered uneconomic by the
2. These results are in general accord with those reported users.
previously for a 25,000 cell population.
5. At this time, it seems appropriate to classify the
3. These results are also in close agreement with a VRLA products as demonstrating acceptable
significant Swedish study of some 35,000 VRLA cells reliability for only 2 years. Beyond 2 years, cell
reported at the 1995 INTELEC. failure rates quickly reach unacceptable levels.