Inspection and Monitoring of

Lead Acid Batteries in

Underground Coal Mines

Koos van Wyk

Anglo Coal South Africa
New Demark Colliery

The Anglo American Conference on Condition Monitoring and Non-destructive Testing

18 & 19 November 2008

1 D2-5
 Order of presentation

• Situation of battery haulers at New Demark Colliery

• Description of some of the associated risks
• Thermal inspection of the batteries
• Advantages if thermal inspection

2 D2-5
 Situation

• Battery haulers were introduced to eliminate the

use of trailing cables
• Additional risks to be mitigated
– Sulphuric acid spills
– Accumulation of hydrogen gasses
– Poor maintenance and maneuvering
– Battery damage and electrical shorts
– Heat generation during battery charging process

3 D2-5
 Risks
• Sulphuric acid spills due to battery damage
– concentration of ± 40% which is strong enough to burn
skin and eyes
– clean-up of spills problematic
– correct equipment must be used when lifting and moving
batteries
• Explosive gasses
– produced during charging
– ventilation becomes extremely important
• Electrical shorts and heat generation
– Battery fire and electrical arcing
– Regular thermal inspection to monitor
4 D2-5
 Thermal Inspection of Batteries

• Thermal imaging used as a tool because of the

following advantages
– Heat generated while charging
– Heat generated while working
– Heat generated while cooling down
• Heating problems can therefore be identified early
and rectified as small changes in temperature are
noticeable

5 D2-5
 Thermal Inspection of Batteries

• Normal battery during cool off period

Note the consistent temperature distribution

over surface area
6 D2-5
 Thermal Inspection of Batteries

• Cell with an internal short

– Abnormally high temperature recorded indicating internal
short between cells

Abnormal temperature Normal temperature

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 Thermal Inspection of Batteries

• Cell with tracking to earth

– Tracking from battery to earth, caused by contamination

Abnormal temperature Normal temperature

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 Thermal Inspection of Batteries

• Faulty cable connections

– Heat generated by the loose connection can be seen in
conductor connection

Abnormal temperature

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 Thermal Inspection of Batteries

• Cell with tracking to earth

– Rising temperature can be noted indicating tracking to
earth, due to contamination or loose connection

Normal temperature Abnormal temperature

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 Thermal Inspection of Batteries

• Cell with tracking to earth

– Due to bad cable re-routing earthing can be detected
possibly as a result of cable damage

Abnormal temperature Normal temperature

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 Thermal Inspection of Batteries

• Damaged trailing cable and loose connection

– Battery supply cable damaged between phases causing
shorting and internal heat

Abnormal temperature Normal temperature

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 Thermal Inspection of Batteries

• Loose terminal connections on batteries

– Shorting between battery terminals due to contamination

Abnormal temperature Normal temperature

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 Thermal Inspection of Batteries

• Loose connections on batteries

– Indication of loose bridge between battery terminals on
installation

Normal temperature Abnormal temperature

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 Thermal Inspection of Batteries

• Battery casing damaged

– Damaged battery casing causing build up of
contamination between body and battery

Normal temperature Abnormal temperature

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 Thermal Inspection of Batteries

• Damaged cells bridged out due to internal damage

– High temperature overload on cells

Normal temperature Abnormal temperature

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 Advantages of thermal inspections

• Safe
– No physical contact
• Immediate assessment of battery condition
– Immediate warnings to operational personnel
• Thermal image recordings of individual battery
packs
• Comparison to previous inspection results

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