NUMBER 25 SPRING 2009 SAFT - saftbatteries.com · NUMBER 25 SPRING 2009 SAFT INTERNATIONAL VISIT EXTREME POWER PAGE 10 Saft Lithium-ion batteries contribute to grid stabilisation

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EXTREME POWER PAGE 10

Saft Lithium-ion batteries contributeto grid stabilisation

Saft performed well in 2008 despite a challenging economic environment and 2009will of course also be difficult due to the market conditions. We are taking the neces-sary decisions to preserve our overall efficiency by seeking operational synergies andkeeping costs under tight control. One such decision is to merge the RBS and IBGdivisions in order to take advantage of under-utilised assets. Our customers will notbe affected by this change, as our sales and support staff will continue to serve themas usual. We remain totally focused on our customers’ businesses, and our short-and medium-term projects continue to progress.

We have expanded capacity in some facilities to meet demand: production capacity for Tel.X telecomnetwork batteries at our Valdosta, Georgia site, and primary lithium cell production as well as Li-ion satellite battery test capacity in Poitiers, France. In addition, Johnson Controls-Saft is in theprocess of increasing capacity for Li-ion hybrid and electric vehicle batteries in Nersac, France.

Saft remains very concentrated on addressing our customers’ needs and seizing the opportuni-ties which develop.

We have flexibility in both development and production and we strive to continually improve ourcompetitiveness.

I am confident that the strengths of Saft will enable us to continue to develop and to accompanyour customers’ progress through these challenging times.

Meeting ourcustomers’ needs

John SearleChairman of the Management BoardSaft 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 ©: iStockphotos/Brian A Jackson • J.Grison/LaCompany • iStockphotos/StephenStrathdee • Ed Doherty • Ford • D.Cocatrix • iStockphotos/James Steidl • iStockphotos/Otmar Smit • Saft • ESA/D.Ducros 2007 • AIRBUS S.A.S. 2008 - ComputerRendering by Fixion - GWLNSD • BT Sweden • Hamburger Hochbahn • Sabik • NLB • Lange Aviation GmbH • DCNS • JSC – ISS • ECA • Cooper Safety • MineTracer TextCommunicator - Photo courtesy of Venture Design Services • iStockphotos/P. Sikora/D. Hristov • Getty images/Malcolm FifeSaft Corporate Communication, 12 rue Sadi Carnot, F-93170 Bagnolet. Ph: +33 (0)1 4993 1707. e-mail: [email protected]

IN THIS ISSUE

Saft begins production ofnew Tel.X telecombatteries

Johnson Controls-Saft begins manufacturing Li-ion

Breakthrough Ni-MH technology for off-grid PV

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Saft Group aroundthe world

16

22

Low-maintenanceNi-MH for shipping-hazardbeacons

20

12

New Hamburg metro relies on Li-ion back-up

Self-launchingsailplane soars forlonger withLi-ion Energy storage for naval craft:

Saft and DCNS in newalliance

19

MATRICS MRX back-up for Oslo airport rail shuttle

Power grids perform betterwith Li-ion storage

system

Saft powers the ATVspacecraft servingthe ISS

24

Li-ionimprovessafety in mines inthe U.S.

Li-ion storage for European on-grid PVproject

4

A350 XWB: first Airbus touse Li-ion battery system

18

10

European ELU Summit to improve reliability

26

New mine-hunter AUV powered by Li-ion

28

Saft Li-ion technology for Russia’s GEO satellites

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ment to this market and we are ready toexpand capacity as demand develops”.

State-of-the art production tool

“Our new Tel.X assembly line – the only dedi-cated Ni-Cd telecom battery line in the world –is semi-automated, using state-of-the-artrobotics and digital controllers”, says Valdostaplant manager Peter Denoncourt. “Poka-yoke(error prevention) has been designed into theline concept, so it is nearly impossible to manu-facture a non-conforming product”.

Saft teamed up with an American systemintegrator, Automation Tool Company, todevelop the semi-automated assembly linefor Tel.X. “This team approach resulted inthe best quality automation, customized forour product”, adds Peter Denoncourt.

Ideal solution for networkapplications

Tel.X batteries are ideally suited for themajority of telecom network applications,including the hardware serving recent trends- cabinets and end terminals in fibre-optic‘triple-play’ networks as well as BTS (BaseTransceiver Station) and BSC (Base StationController) installations in wireless networks.This means equipment that is often inremote or demanding outdoor locations.

Saft’s focus is on providing a high qualitybattery solution for applications that aresubjected to extreme temperature as well ashigh levels of humidity. Other key Tel.Xfeatures are:• maintenance-free under normal oper-ating conditions, so ideal for remote sites• compact, light and easy to install;around 15 minutes for a 48 V battery• exceptionally long service life, over 20years in normal temperatures and morethan 14 years at +40°C• wide range of capacities• high volumic energy density of up to100 Wh/L while weighing around 30%less than a conventional battery• designed for use in standard 19” and23” racks and cabinets, where its size

PAGE 4 SAFT INTERNATIONAL

STRATEGY

The Tel.X range is designed to deliver reli-able backup power for the growing numberof decentralized telecom facilities supportingfixed, wireless, cable and cellular networks.Tel.X is the result of a 2-year developmentproject led by the Valdosta team, with strongsupport from Saft’s Bordeaux and Nersacsites.

The new manufacturing line, which has acapacity of over 16,000 48 V Tel.Xbatteries per year, will enable Saft to expandits customer base in a market whereperformance, reliability and low total cost ofownership (TCO) are crucial.

“Saft is already a significant player in thismarket, which has considerable growthpotential”, says Xavier Delacroix, GeneralManager of Saft’s IBG division. “Our newproduction line shows our strong commit- [email protected]

SAFT INTERNATIONAL PAGE 5

Saft starts productionof new Tel.X batteriespurpose-designed for telecom networks

makes it easy to install as a directreplacement for VRLA batteries• compatible with all telecom rectifiers.

Ongoing field trials

Tel.X batteries are currently being testedby a number of customers around theworld, and Saft technicians have beendirectly involved in many field trials,

conducting the electrical tests on-site. The market for this type of battery hasbeen primarily an American one, so far butis expected to rapidly expand to otherzones. However, Valdosta is prepared toship orders to customers anywhere in theworld.

In January 2009 Saftstarted up its new $9-million production line atits US manufacturingplant in Valdosta(Georgia). The line isdedicated to Saft’s newTel.X nickel-basedproduct range designedspecifically for telecomapplications.

On 29th January 2009. Saft officials with telecom customers and Valdosta Chamber of Commerce staff

and increasing interest in PHEVs and EVs.With this state-of-the-art facility, JohnsonControls-Saft is set to become a majorsupplier of HEV/EV batteries”.

Major contracts

Johnson Controls Vice President AlexMolinaroli outlines what the “excellent match”joint venture had already achieved in this keymarket: “In 2007 General Motors awardedus a development contract for batteries of

the Saturn Vue Green line plug-in hybrid SUV,and in August we won the contract to supplyLi-ion battery packs for a test fleet of DodgeSprinter plug-in hybrid delivery vans. Then inJanuary 2008 the joint venture won two newcontracts for the Chinese market. JohnsonControls-Saft was selected by China’s leadingcar maker, SAIC, to provide Li-ion batteriesfor its demonstration fleet of new energyvehicles. We will be also be producing Ni-MHbatteries for Chery Automobile’s new A5 mildhybrid, which will be available to consumersin 2010”.


MARKETS

The 2,000-sq.m Nersac plant, whichrequired investment of €15 million, has thecapacity to produce up to 10,000 batterypacks (350,000 cells) per year and is builtto be scaleable so that production can beincreased to meet growing demand fromauto manufacturers. Johnson Controls-Saftis now on the way to becoming a leadingworld player and no.1 Western supplier inthis high-growth segment.

A high-potential market, driven byenvironmental concerns

Saft President and CEO John Searledescribes the new plant as a confidentinvestment in the future, explaining that“The market for clean vehicles has enormouspotential. In Europe, all car makers havestated their intention of developing thesevehicles and Li-ion technology is now recog-nized as the way to go. Studies estimatesales of around 4 million hybrids by 2015


Johnson Controls-Saft begins manufacturing Li-ion batteries for hybrids

In 2008, Johnson Controls-Saft inaugurated its new Li-ion line at Nersac, France.The plant, which manufactures advanced Li-ion batteries for hybrid, plug-in andelectric vehicles, is the first of its kind in the world. Batteries from Nersac will soonbe powering the new Mercedes-Benz S-Class hybrid sedan to be launched in June2009. Johnson Controls-Saft is set to become the leading Westernmanufacturer of batteries for hybrid and electric vehicles.

Johnson Controls-Saft -Comprehensive expertise Johnson Controls-Saft is a jointventure set up in early 2006between Johnson Controls, theworld’s leading supplier of automo-tive batteries and a company withlong experience in integrated auto-motive systems, and Saft, anadvanced energy-storage solutionsprovider with extensive Li-ionbattery expertise.Saft brings into the partnership its Ni-MH cylindrical-cell and Li-ion technolo-gies and Johnson Controls contributesits systems-integration know-how, its Li-ion laboratory in the US and its exten-sive knowledge of the world autoindustry.

The joint venture’s expertise covers the full package:- Cell chemistry and design- Cell manufacturing- System engineering (mechanical, elec-tronics and SW, electrical, validation)- Integration- JIT assembly.Johnson Controls-Saft has built up aglobal footprint so as to be moreaccessible to customers. In addition tothe plant in Nersac, the company hasR&D centres in Milwaukee (USA) andBordeaux (France) as well as systemengineering, testing and integrationcentres in Milwaukee, Hanover(Germany) and Shanghai (China).

Excellence inmanufacturingAt Nersac, Johnson Controls-Saft has merged themanufacturing excellence of both mother companies.Nersac has launched a full manufacturing efficiencyprogramme covering everything from equipmentdesign to process improvement. For instance, Li-ioncells are very sensitive to moisture, which can impactthe performance of the battery. “We have built one ofthe largest and most efficient dry rooms in Europe,with airlock doors for personnel and materials toprevent atmospheric moisture from entering”,explains Operations Manager Thierry Bouilleau. “Butthat’s not enough; we also have special clothes forthe operators and we set strict rules to apply at eachstep of the processes. We are already in the secondphase of process improvement, aimed at minimizingthe water content in our components. Excellence inoperations will be one of the critical success factorsin optimizing our overall performance and meetingcustomers’ expectations”.

Ford’s Escape Hybrid Plug-in with a Li-ionbattery supplied by Johnson Controls-Saft

see page 8


MARKETS

[email protected]

High power application8 yr life announcedManufacturing capacity available in JapanKey component of cost - Nickel

HEVNi-MH

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High power applicationSmaller, lighter batteriesVery long life demonstrated by SaftPotentially lower cost with high volume

High energy applicationRange up to 30 - 200 kmZero emission in EV mode

High power application to aid accelerationDemonstrator fleets being planned


Since then the company has announced:

• a BMW production contract to supply Li-ionbatteries to power the ActiveHybrid 7 Series,

• a production contract with Azure in the USrepresenting the plant’s first success in thecommercial vehicle segment,

• a production contract with Ford for its firstplug-in vehicle.

Going for 100% quality Battery technologies for hybrid vehicles

HEVLi-ion

EVLi-ion

WithFuel cells

Mild HybridFull Hybrid

Plug-in Hybridand Electric Vehicle

Electric Vehicle

Mild HybridFull Hybrid

Chemistry Battery characteristics Applications

“It’s a matter of battery lifetime”,explains Pascal Lafaye. “Today’s carbatteries are only expected to last 3 to4 years. But firms manufacturinghybrids want batteries that last the lifeof the car, meaning around ten years.To achieve this, you have to completelyeliminate defects”. So at the Nersacplant, Johnson Controls-Saft hasalready received the ISO-TS certifica-tion. “This increases the confidence ofour automotive customers. We havereceived the green light from Daimlerto launch series production of our firstlithium-ion hybrid battery. We are

using a new preventive tool to analyseand reduce risk. This starts with theequipment, because if you have low-quality equipment you get low-qualitymanufacturing. It also covers carefulselection of suppliers (i.e. auditingtheir QC procedures too) and trainingline personnel to perform systematicquality controls at every stage of themanufacturing process - electrodepreparation and assembly”.

Johnson Controls-Saft is currentlylaunching capacity expansion in Nersac tomeet demand. 2009 has also seen amarket initiative from several governmentsto accelerate the development of clean vehi-cles, which should stimulate demand.

Saft: auto-industry partner andLi-ion leader

Saft’s involvement in supplying batteries tothe motor industry dates back to the 1990swhen the company started to produce Ni-CdEV batteries in Bordeaux for Peugeot-Citroën(PSA) and Renault. This project was a limited

“With hybrid and EVbatteries, quality is every-thing”, says Pascal Lafaye,Quality Manager,Automotive, who heads thejoint venture’s 7-man QCteam. Even though Saftalready has very high stan-dards (ISO 9001),customers insisted on evengreater emphasis onquality.

success as the range of the car betweenrecharges was too short, but this encour-aged Saft in 1995 to start work on devel-oping advanced technologies such as Ni-MHand Li-ion, again in our R&D centre inBordeaux. Later, this work was extended todevelop high-power Li-ion technology forHEVs and other applications, and this tech-nology has become the basis of the batteries

Johnson Controls-Saft are producing on thisnew site. Over the last 10 years, Saft hasinvested an estimated €120 million in devel-oping its Li-ion technology, which is also usedin our traditional activities for the space,aviation and defence markets.

1 • Coating line2 • Cell assembly line

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[email protected]

Ni-MH

Li-ion

Li-ion

Li-ion

“The key aim is to demonstrate the feasi-bility and added value of incorporating Li-ionenergy storage within a FACTS system”, saysPer Eckemark, Head of ABB’s FACTS SystemGroup. “It could play a vital role in ensuringthe stability of utility grids as the penetrationof wind power increases”

Li-ion battery system

Li-ion technology brings a number ofadvantages to this application: excellentcycling capability; long calendar life; highenergy density; very short response time;high power capability in both charge anddischarge; maintenance-free design. Saft’stechnology also provides the system withprecise information on state of charge(SOC), which is a vital function in a dynami-cally operating energy storage system.

The battery system comprises eightstacks of Saft’s Intensium Flex, rack-mountedLi-ion modules. Each stack involved 13modules and a control unit (BMC). Nominalvoltage is 5.2 kV and the system can deliveractive power of 200 kW for an hour and600 kW for over 15 minutes. Saft is alsosupplying the control and managementdevices for the battery, as well as a CAN-based optical communication interface withABB’s MACH-2 controller that will monitorthe battery continuously and optimise itsoperation.


EXTREME POWER

Increasing use of wind and solar power is definitely a plus for ourplanet’s environment, but feeding these variable power currentsinto existing distribution networks can destabilise the grids. Saftand ABB have a solution.

The two partners have scored a worldfirst by developing a 5,200-volt dynamic Li-ion energy-storage solution to minimise griddisruptions in particular due to theincreasing penetration of renewables.

Power transmission systems are subjectto voltage and load variations, and thisphenomenon is becoming more serious asincreasing numbers of renewable sources(wind farms, solar PV systems…) arebrought on line. This instability reduces agrid’s transmission efficiency. Current tech-nology allows utilities to stabilise voltage vari-ations. But ABB, the world’s leadingspecialist in AC systems to stabilise powergrids, such as the company’s FACTS (FlexibleAC Transmission Systems) range, haslaunched a project to increase their scope tocover short-term load variations by adding abattery energy storage device to theirsystem. The new system will be most usefulto industries with high short-term powerdemands and grids with a high penetrationof intermittent renewable energies.

More efficient use of renewablesources

The new solution, called DYNAPOW,combines dynamic energy storage provided bySaft’s 5.2-kV battery, which will help respondto disruptions in the grid, with ABB’s SVC(Static Var Compensation) Light high-frequencyswitching technology for dynamic voltagecontrol. While current FACTS technology isfocused primarily on stabilising grid voltage,the addition of energy storage also allows it tocover short-term supply or load variations.

valuable input, and Saft engineers alsoplayed an active role during qualification andtesting of the complete system”.

Testing and a pilot fielddemonstration…

The battery system has successfullycompleted commissioning and bench testingat ABB’s facilities in Sweden. The next stage,a pilot project due to begin in March 2009,will involve installation of an SVC Light withdynamic energy storage in an EDF Energydistribution network in Britain (betweenOrmesby and Martham in Norfolk), whichhas a high penetration of wind power.

The Martham pilot will deliver dynamicvoltage control in an 11 kV grid and at thesame time enable dynamic storage of

surplus energy from nearby wind farms,energy that can be used to level out peaks ingrid loading.

“This installation will improve the usabilityof power from the wind farms and avoid thedestabilising effect it can have on the grid”,says Per Eckemark. “It will also provide auseful reference project for energy storage”.

… and then moving up to the nextlevel

Looking further ahead, Saft is now workingwith ABB on full-scale applications involvingtens of kV and tens of MW.

New high-voltage Li-ionbatteries help improvestability of power gridswhile optimisingrenewable sources

Development partner

“We chose Saft for two reasons”, saysFACTS Group R&D Manager PeterLundberg. “Their Li-ion batteries have thehigh power and high density our applicationneeded, and over the past 10 years we havefound Saft to be a good technical andcommercial partner. We looked around, andSaft was the right company with the righttechnology”. But ABB was not just looking fora battery manufacturer. “We were devel-oping an innovative solution where batterystorage is a key element, so we needed adevelopment partner who knew aboutbattery management systems and integra-tion into applications”, adds Peter Lundberg.“Saft worked with us to adapt their productsto our application. People from theirBordeaux facility came to Sweden to provide

[email protected]



Germany and 50 systems in France(including French overseas territories).

“Teamwork is essential in projects likethis”, says Tenesol R&D projects coordinatorJean-Christian Marcel. “Saft engineers areworking very closely with Tenesol andVoltwerk on development of our system-management interfaces. Saft experts makefrequent visits to Lyon and Hamburg. It is avery fruitful partnership. Both we and Saftare learning a lot”.

“Once the systems are installed, actualtrials will last 12 months”, explains ManfredDittmer, Head of Innovation at Voltwerk.“Then we will start improving our systems byapplying the lessons we have learnt. We areconfident we will end up with a goodcommercial product”.

Li-ion technology

“Sol-ion was initiated by Saft following anongoing partnership with Tenesol, Technofi

and the French power utility EDF on aproject in Guadeloupe to test the technicalfeasibility and economic advantages of Li-ionstorage coupled with grid-connected PVsystems”, says Jean-Christian Marcel. “Nowwe have joined forces with Voltwerk to lookat the self-consumption aspects too”.

“We needed batteries that could handlehigh cycling and fluctuating charge anddischarge, and do this for at least 20years”, explains Manfred Dittmer. “Li-iontechnology has the right energy perform-ance as well as good total cost of ownership(PV end-users look very closely at the capex-lifetime equation) and Li-ion is well suited tothe battery-management systems werequired”.

Enhancing efficiency andeconomics

The concept being tested by Sol-ion hasstrong market potential. On-grid systems

are the most popular solar PV solutions forhomes and businesses in developed coun-tries. Energy storage will make thesesystems more efficient because excess PVenergy can be stored until it is needed,whether locally or on the grid. Batteries will“time-shift” the energy produced during theday, making it available on demand whenneeded. This will maximize self-consumptionand also increase the return for the ownerof the PV system because of a special finan-cial bonus for self-consumption underGerman law. Furthermore, energy storagewill increase home and business security ofsupply.

Last and certainly not least, this newconcept will help drive the development ofenergy-self-sufficient houses and other build-ings and contribute to the further growth ofrenewable energies as part of the globalenergy mix.

“Given the current climate change issueand the recent energy price volatility, thereis an urgent need to move ahead fast withrenewables”, concludes Manfred Dittmer.“To do this, we have to combine topexpertise, and preferably at internationallevel. That’s what we’re doing with Sol-ion”.

shifted” to periods when there is no sun.This enables the system to maximise ahousehold’s self-consumption of PV energy(in accordance with the new German feed-intariffs), with only minimum impact on thegrid. The project will demonstrate the bene-fits to the environment and to stakeholdersof storing PV energy. One key benefit will beto reduce the impact of intermittent injectionto power grids, thus allowing a high penetra-tion rate of PV energy in the electricity mix.

Li-ion is the only technology that meetsthe project’s need for 20-year battery life indemanding environmental conditions

Leveraging partnership expertise

Saft’s partners in the project are leadingPV systems providers and integrators:Germany’s Voltwerk (a subsidiary of Conergy AG,

The Franco-German Sol-ion partnership,launched in August 2008, is developing anintegrated energy kit able to be produced onan industrial scale for decentralised on-grid,residential PV systems.

Li-ion batteries will be used in PV systemson the biggest scale ever tested in Europe:75 systems will be deployed in France andGermany to assess the performance of thetechnology, its economic viability, the addedvalue of energy storage in an on-grid systemand the benefits to stakeholders.

Validating a new concept

Most grid-connected PV systems do notinclude energy storage and the electricityproduced is fed into the grid directly, in realtime. The advantage of the Sol-ion storageconcept is that solar energy can be “time-

an integrated PV company), which hasinstalled more than 70,000 systems in 20countries; and France’s Tenesol (a subsidiaryof the energy group Total and the powerutility EDF), which supplies integrated photo-voltaic systems and also manufactures solarpanels (100 MWp forecast in 2009).

Saft is providing Li-on battery modulesthat will be connected in series to obtain theenergy and voltage required by the applica-tion. The Intensium Flex modules will includeelectronics for data acquisition (voltage,temperature, etc.) and cell balancing inorder to optimise battery life and allowcharge/discharge control. System-manage-ment interfaces are being developed jointlywith Tenesol and Voltwerk, which willproduce the other components andassemble the Sol-ion product (battery +inverter + system management). 25 systems will be produced and set up in

[email protected]

Saft has now teamed up with Voltwerk and Tenesol in the EU-backed Sol-ion projectto develop a new concept in energy conversion and storage for grid-connectedphotovoltaic (PV) systems.

Li-ion storage for Europe’ s largest photovoltaic energy project

INNOVATION


Wide-rangingpartnership

Sol-ion has been recognised by the EU

Eureka/Eurogia programme and has the

support of the French Ministry of

Economy, Finance and Employment and

the German Ministry of Environment. Also

associated with the Sol-ion project are a

German power utility E-ON and four

German and French research institutes.

with safety qualifications for manned flightmissions. This is important, because whilethe ATVs travel as unmanned automatedspace vehicles, once docked they function asan integral part of the manned space station.Two primary lithium batteries will play a keyrole by supplying power for the separation ofthe ATVs from the ISS at the end of theirmission, while two other identical batterieswill power the emergency procedures.

Rechargeable Ni-Cd batteries

100 minutes after lift-off, the ATVsbecome fully automated spacecraft navi-gating towards the ISS. During this phase,their main power is derived from four largesolar wings with backup provided by fournickel-cadmium (Ni-Cd) batteries. Once thecraft docks, the Ni-Cd batteries continue toprovide power for the ATV during theapproximately 30-minute periods of each90-minute orbit that its solar panels areeclipsed by the Earth’s shadow.

Saft Ni-Cd batteries offer a particularlyrobust and reliable solution for this applica-tion, with a spaceflight heritage that goesback over 40 years. “Saft has developed anoutstanding track record in delivering reli-able, high performance batteries for satel-lites and launch vehicles. Now, with thisfirst ATV mission, we have proved ourability to transfer this expertise to mannedflight vehicles”, says Philippe Jehanno,


EXTREME POWER

Saft supplied specialised primary lithium and rechargeable Ni-Cdbatteries to support vital functions on the first European spacecraftto dock with the ISS.

Saft primary and rechargeable spaceflightbatteries powered the ATV (AutomatedTransfer Vehicle) Jules Verne, the most chal-lenging spacecraft ever engineered andproduced in Europe, on its mission to re-supply the International Space Station. InMarch 2008, the 19,4-tonne ATV, devel-oped for the European Space Agency (ESA)by EADS ASTRIUM Space Transportation asthe prime contractor, was placed success-fully in a low earth orbit by an Ariane-5vehicle launched from the Kourou spaceportin French Guyana.

The ATV, ferrying a load of propellants,food, water and scientific equipment intospace, was the first European spacecraft todock autonomously with the ISS. Once inplace, the Jules Verne became an extensionof the space station, orbiting about 300 kilo-

metres above the Earth. When its “flaw-less” 6-month mission was completed on29 September, the craft was loaded with6.5 tonnes of waste and it separated fromthe space station to fully burn up during a“controlled destructive re-entry” to theatmosphere high over the Pacific Ocean.

The Jules Verne was the first in aprogramme of five ATVs planned to re-supply the ISS at approximately 12-monthintervals. The next ATV, Johannes Kepler,is now in production at the Astrium site inBremen (Germany) and is scheduled forlaunch mid-2010 on an Ariane 5.

Saft designed, developed and suppliedall eight onboard primary and recharge-able batteries required for the JulesVerne, and has a long-term contract withEADS ASTRIUM Space Transportation tosupply all the batteries for future ATVmissions until 2011. Saft’s experience inthe management of battery developmentprojects is a vital element in the successof this complex programme, whichrequired the coordination of a number ofmanufacturing sites and two differentbattery technologies.

Primary lithium batteries

Saft primary lithium (Li-MnO2) batteriesoffer a particular advantage for spacecraftas their high specific energy helps toreduce the overall weight. They also comply


technology for every spaceflight applica-tion.”

The ATV batteries were designed andmanufactured by Saft’s plant in Poitiers,France, with the support of its Bordeaux

Saft batteries power the ATV Jules Verne on its mission to resupply the International Space Station

General Manager of Saft’s Poitiers produc-tion site. “Furthermore, supplying primarylithium and Ni-Cd batteries has enabled usto demonstrate the scope of our productportfolio, which includes the ideal battery [email protected]

plant for the Ni-Cd batteries and theBüdingen plant in Germany for the primarylithium cells


Specialty Battery Group production siteHigh-performance, primary and rechargeable batteries for electronic, defence and space applications.

Industrial Battery Group production siteNickel-based rechargeable batteries and new technology batteries for industrial applications.

Rechargeable Battery Systems production siteSmall-format, nickel-based rechargeable batteries for professional applications.

Saft sales network

ASB (50% Saft, 50% EADS)

Johnson Controls-Saft (Saft 49%, Johnson Controls Inc. 51%)


The Saft Group around the world

[email protected]


Faced with increasingly stringent require-ments regarding performance, reliability andlow maintenance, BombardierTransportation turned to Saft’s specialisedrechargeable Ni-Cd on-board batterysystems for the upgrade of the high-speedairport rail link. The upgrade was needed toprovide additional passenger capacity forFlytoget’s service, which already carried athird of all passengers using the airport (4.9million passengers in 2006 and 5.4 millionin 2007).

Major upgrade in 2008

During 2008, the fleet of 16 three-carBombardier BM71 electric multiple units(BMUs) were given an extra coach to createfour-car units. Bombardier asked Saft toprovide not only MATRICS MRX units for thenew coaches but also replacement batteriesfor the existing 48 cars – a total of 64battery systems.

The primary role of the 110 V batterysystems is to supply emergency back-uppower for essential on-board systems suchas lighting, ventilation, air-conditioning, dooropening and communications to maintain

passenger comfort and safety in the event ofmains power failure.

Reliable back-up power

The batteries are supplied as part of a fully-integrated battery system comprising 2custom-designed battery boxes with 42 MRXcells each.

The Flytoget service, which began withthe opening of Oslo’s new airport in 1998, isthe only high-speed (210 kmh or 130 mph)rail service in operation in Norway. It whisks

Bombardier haschosen Saft’sMATRICS MRXbatteries to upgradeFlytoget’s high-speedAirport Express train running from Osloto Gardemoeninternationalairport.

Ni-Cd reliability and performance for Osloairport's Bombardier shuttle

passengers from Gardemoen, 50 kilometres(31 miles) north of the capital, to OsloCentral Station is 19 minutes. Trainsnormally operate every ten minutes, with halfthe services continuing westwards to Asker.These serve eight stops within Greater Oslo,with plans to extend to Drammen in 2009.Founded in 1992 as a subsidiary of theNorwegian State Railways, Flytoget has beenowned by the Norwegian Ministry of Tradeand Industry since 2001.

Purpose-designed back-up solution

Saft MATRICS MRX batteries are purpose designed for rail applications to delivermaximum performance and reliability as well as low total cost of ownership (TCO). They offer low maintenance and long service life, thanks to sintered /PBE technology in acompact, lightweight battery pack that brings a significant size and volume advantagecompared with conventional batteries. As an added plus, Saft’s Ni-Cd batteries canoperate reliably in extreme temperatures (-30°C to +70°C) without suffering from the“sudden death” phenomenon that affects some battery technologies. MRX solutions arealso in service aboard the Karlsruhe tram-train, the Hamburg metro, the new Paris ring-tram and France’s record-breaking TGV high-speed train.

of Saft’s 10+ years of research in advancedLi-ion battery technology for specific,demanding applications. This joint effort willalso enlarge the portfolio of technologiesavailable for adaptation to each futureaircraft programme.

“Li-ion battery systems, with their toppower-to-weight ratio, are likely to be thepreferred solution for the new generation oflong-haul passenger aircraft, where weight(i.e. fuel consumption) is a very high priority”,says Bernard Weber. “The majority ofaircraft will continue to rely on back-up fromNi-Cd batteries for at least another 20years, but there is a growing role for inte-grated Li-ion battery systems in next-genera-tion long-haul aircraft, where weight is socrucial”.

Conceived as a medium-capacity long-haulaircraft, the A350 XWB (Extra Wide Body)will be available in three basic versions,carrying up to 350 passengers.


TECHNOLOGIES

New Li-ion battery system fornew-generation Airbus A350 XWBRapidly rising fuel costs are leading makers of new-generation passenger planeslike the Airbus A350 XWB to look closely at economics. They are opting forlighter materials, fuel-efficient engines and now Saft Li-ion back-up batteries withtheir top power-to-weight ratio.

Saft has now been chosen by Airbus todevelop and supply a lithium-ion batterysystem as the starting and emergencypower supply on the A350 XWB aircraft.This is a significant milestone for Saft: thefirst Li-ion battery system aboard a commer-cial aircraft.

Li-ion batteries are lighter, helping toreduce fuel costs, and maintenance-free,helping to cut operating costs. The Saftbatteries will be used to start the auxiliarypower unit (APU) and provide emergencyback-up power for crucial avionics.

Systems integration

The battery system offers a truly innova-tive solution and includes an integrated moni-toring and charging system using proprietarySaft know-how in the relevant electrochem-istry algorithms. The new battery system willbe connected to the DC bus, thanks to anintegrated charge control and monitoringsystem. It features both state-of-health (SOH)and state-of-charge (SOC) indicators andcommunicates with the aircraft’s manage-

ment system, giving pilots even bettercontrol of the aircraft.

“Saft was involved in the design of theelectrical system from very early on, furtherto Airbus NSP (New System Policy), helpingAirbus to define the optimum battery systemfor the plane’s requirements”, says SaftAviation Director Bernard Weber. “We arenow in a 3-year development phase whereSaft’s Bordeaux engineering team is workingclosely with Airbus engineers in Madrid andToulouse to develop a mature solution withno risk of teething problems”.

Long-standing partnership

As supplier of back-up batteries to Airbus,Saft has been cooperating on alkaline tech-nologies since the origin of Airbus aircraft inthe 70s. Saft provided the batteries thatequip the new A380 that went into servicein 2007. At the same time, Saft has built upleading-edge expertise in Li-ion batterysystems. This will be the first programme inAirbus’ history to use this new batterysystem, illustrating the successful adaptation [email protected]

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Out of your car and into themetro!

The DT5 trainsets have open gangways,allowing passengers to move freely from oneend of the train to the other. And in a bid toget more car-drivers to switch to publictransport, the city looked for increasedpassenger comfort and enhanced safety.Other features include dedicated areas forprams and wheelchairs, full air-conditioning,passenger information system with largeLCD displays, fire sprinkler system, highrecycling rate of the materials used, andnoise-optimisation thanks to quiet, water-cooled, 3-phase AC traction motors.

Saft’s MATRICS MRX batteries provideback-up power for the safety and controlcircuits of the trains when they pass throughneutral sections of track, and they ensureemergency power for functions such as dooropening and communications in case ofmains power failure. MRX was purpose-designed for this application and can provide1-hour back-up power at an extreme -20°C.Each 3-car DT5 train will have one battery,housed under the floor in a box speciallydesigned by Alstom.

Purpose-designed batteries

The batteries in the DT5s are19 MRX230,delivering 230 Ah at 24V. The key criteria in


Hamburg Hochbahn’s new - generation metro trainsrely on purpose-developedNi-Cd batteriesfor back-up power

When Hamburger Hochbahn was callingtenders for construction of new trains forthe port city’s new metro line, it specifiedthat all tenderers were to use Saft…Bombardier, a Saft customer for over 20years now, was more than happy to goalong. For the electrics of Hamburg’s new-generation trainsets, the leading transportOEM selected Saft’s latest Ni-Cd railwaybattery system technology, MATRICS MRX.

Mass transit aiding urban development

Hamburg’s new DT5 trains will be deliv-ered from 2009 to 2013. They will startoperating on the existing U3 line and, as ofend 2011 some of the DT5 fleet will be used

on the new U4 line connection between theemerging quarter of HafenCity (one ofEurope’s most modern urban centres) andHamburg’s city centre. The new line will runmainly underground, except for a fewsections in eastern Hamburg.

The trainsets are being built by a consor-tium of two regular Saft customers, Alstomand Bombardier. Alstom is building the stain-less steel car bodies, the bogies and thebrakes, while Bombardier is supplying theelectrical equipment. Hamburger Hochbahnhas ordered 27 trains, each comprisingthree cars, with an option for another 40.The same consortium (and batterysupplier…) delivered the successful DT4previous generation, and Saft’s Ni-Cdbatteries have an outstanding track recordfor performance and reliability.

Today’s urban railway operators are taking a long hard look at energyconsumption and operational efficiency as well. So when OEMs are doingthe engineering and selecting suppliers, they look for reduced weightand volume, along with high reliability and low maintenance. Thatapplies to batteries too, and Ni-Cd fits the bill perfectly.


The battery of preference

Saft’s MRX-type batteries, with their

reduced weight and volume and their low

TCO (total cost of ownership), are

proving extremely popular with rail oper-

ators and OEMs. During 2007, Hitachi

chose Saft for the UK’s Channel Tunnel

Rail Link project, French Railways (SNCF)

switched from lead-acid to MRX batteries

for all its Alstom TGV Duplex (2-level)

passenger coaches, Siemens preferred

MRX for its new Eurosprinter family of

electric locomotives, and Spanish Railways

(RENFE) selected MRX for its new Civia

electric trainsets being built by Siemens,

CAF and Alstom.

Partnerships for progress

21st-century transport, with its increased focus on weight and size, is a chal-lenging segment and also a strategic area for Saft, which is the leading supplierof Ni-Cd batteries for transport applications. Saft is proud to be present in thisnew generation of electric vehicles alongside major players like Bombardier andAlstom. In a recent example of this partnership, MRX-type batteries provided back-up power for auxiliaries and braking when an Alstom-built French Railways high-speed train (TGV) smashed the world rail speed record in 2007.

battery selection were reduced weight andvolume, as well as low maintenance. In addi-tion, as the U4 line runs partly underground,fire prevention was a major factor. Masstransit operators are increasingly concernedabout fire underground, and Bombardierspecified flame-retardant plastic for all thebattery cells.

Saft’s MRX solution offers mass-transitOEMs significant flexibility too: a range of 90-,100- or 115-Ah cells can be selected andassembled in the same battery box so as tovary the battery’s capacity to meet specificproject needs. These can extend to largercapacity for lower operating temperatures.

[email protected]

MRX: flexibility and reliability

Saft’s MATRICS MRX solution is alsoextremely reliable. It does not suffer fromthe “sudden death” phenomenon that canafflict other technologies and it operates intemperatures from -30°C to +70°C.

The batteries also have a central water-filling system for easy maintenance. Thissimple-to-use feature fills all the cells insequence from one central point, allowingthe cells to be filled quickly, safely and accu-rately and so maximising the battery’sservice life.

in shallow-water zones like the North Sea arebuilt on fixed concrete gravity bases. In thiscase decommissioning involves removal ofthe main superstructure (topsides andjacket), leaving only the concrete base, whichneeds to be marked as a hazard to shipping.

For nearly three years now, Saft Ni-MHbatteries have been powering the Sabik Self-Contained 10 NM Lights (actually light+radarsystems) installed on four abandoned oil plat-forms out in the North Sea, systems thatwarn approaching vessels of the hazard.

These maintenance-free and remotely-monitored light units, the first of their kind inthe world, are made by a German company,Sabik Informationsysteme, which specialisesin light-based signalling systems (for lockgates, port entrances, swing bridges)including those requiring remote monitoring(navigation hazards, lighthouses).

Light, racon and satellitemonitoring

Sabik’s stand-alone unit comprises a LEDlantern (and sometimes two) for visualwarning (the light is visible for 10 nauticalmiles), a racon (radar transponder) beaconfor low-visibility recognition and a satellitemonitoring unit. Sabik has delivered 8systems to mark 4 Total platforms on theFrigg field in the Norwegian North Sea. Thisis a critical application so there is a back-up

Oil companies have been producingoffshore for decades and the world’s oil andgas basins are dotted with thousands ofproduction platforms, either floating or fixed.But most oil and gas fields only produce for20 to 30 years and increasing numbers ofoffshore fields are becoming depleted. Whenthis happens, the platforms are decommis-sioned and oil companies usually dismantlethem or tow them away. But some platforms

4- years maintenance-free operation

The unit is installed by helicopter and fitson a special docking pole bolted to the plat-form to ensure that the unit is positionedwith the solar panels facing in the right direc-tion. Once the light is in place, there is noneed for maintenance. The Sabik units areengineered to operate maintenance-free for4 years, with an overall lifetime of 15 years.Vital systems all include redundancy and theunit has separate photovoltaic (PV) systemsto ensure reliable recharging. Operation ismonitored via a satellite-based system thatprovides detailed information about the

unit onshore ready to be helicoptered out ineach case. All are operating satisfactorily.

Saft batteries based on NHE modulesprovide back-up power for all functions: light (12V 500 Ah = 5 x NHE2-500); racon (12V 300 Ah = 3 x NHE12-100) and monitoring (12V 100 Ah = 1 x NHE12-100).


EVOLVING PLANET

Low-maintenance Ni-MH+ PV combination isideal for shipping-hazardwarning lights

[email protected]

Saft batteries, recharged using solar panels, have been chosen by specialist firmSabik to provide reliable power for maintenance-free navigation-hazard lights onabandoned offshore structures in the gruelling North Sea.

The U.S. CoastGuard too…

In 2007, Saft Li-ion batteries were also

chosen by BWT Lighting for the self-

contained solar-powered navigational

lanterns in the fixed-aid and buoy

lanterns it supplies to the U.S. Coast

Guard. These batteries – solar-

rechargeable, minimum-maintenance

and long-lifetime – are ideal for this

application and will also outperform

other battery chemistries in the harsh

marine environment.

performance of all on-board systems. In thecase of the Total platforms, the NorthernLighthouse Board is responsible for moni-toring.

Weight, reliability and service life

As the system has to operate for yearswithout maintenance (helicopter transport isexpensive…) and has to be both light andcompact enough to transport, the choice ofbattery was crucial. “There were three maincriteria”, says the firm’s Managing DirectorMorten Christensen. “The key issue wasweight, as our system had to be transportedby helicopter. Then came reliability and longservice life. Ni-MH was chosen for its weightand size advantage. This is a critical applica-tion: we needed the best and were preparedto pay a premium”.

“Saft was strongly recommended to ourcustomer Total by the Northern LighthouseBoard”, adds Mr Christensen. NLB had itselfbeen a Saft customer for many years, andSabik’s Finnish parent group had also beenbuying Saft batteries for more than 10years, for use in Scandinavian lighthouses.“Not only are the batteries performing well,but Saft’s French and German teams gaveus really good technical support in the earlyphases of the project, with battery sizing, forexample. They even sent an engineer from

Tough standards for tough conditions

As units like Sabik’s Self-Contained 10 NM

Light are key elements in maritime safety

(especially in the often stormy North Sea)

the design and performance of the unit

and all its components is based on tough

criteria laid down by the relevant maritime

authorities: Norway’s Coastal

Administration (Kystverket) and Scotland’s

Northern Lighthouse Board.

Bordeaux to advise on installation andcharging. They were very keen that every-thing was done right so we would get thevery long lifetime we needed”.

Actions speak even louder than words: inmid-February 2008, Sabik placed anotherorder for Saft batteries for the same kind ofapplication.

Main Lantern

Backup Lantern

RACON

PhotovoltaicModules

Docking Pole


EXTREME POWER


machine’s performance, so they asked Saftto provide lighter, more powerful Li-ionbatteries instead. Lange also revised andsimplified the glider’s electronics to make thesystem fully reliable, earning German AviationAuthority (LBA) certification as a manufac-turer.

World records

Lange’s move up-market pleased thefirm’s customers too, as the Antares “motor-glider of the future” gained both altitude andrange. Some 45 of the gliders have beendelivered so far. “Saft’s challenge was to helpLange get their product into the winningclass”, says Saft’s German representativeHolger Schuh. Mission accomplished: in April2007, an Antares 20E set several records,including a British distance record of 1,141kilometres, in 10 and a half hours.

The 20-m wingspan Antares is equippedwith a high-performance, almost silent42kW (56hp) brushless electric motor and aslowly-revolving 2-metre diameter pusher


Several years ago German firm LangeFlugzeugbau, which produces a range ofgliders at its production facilities inZweibrücken, launched a prototype Antarese-powered glider with Ni-MH batteries. Whyelectric? “Because 2-stroke engines don’talways start when you need them to”, saysthe firm’s founder and CEO Axel Lange. Butthe company was not fully satisfied with the

Outclimbing the competition

At the most energy-efficient power setting, the Antares can reach 1,000 metres– twice the height achieved by a good winch launch – in under 4 minutes. The battery system can provide about 13 minutes of maximum power, which willtake the glider to over 3,000 metres. Even in no-lift conditions the craft, whosepublished glide ratio is an impressive 1:56, will then take an hour and 40 minutesto glide back to earth.

For years, gliders were laboriously winched or towed into the air. Today theyoften have a motor and propeller for take-off and climb. The key challenge here is obviously to optimise the power-to-weight ratio. A high-energy,lightweight rechargeable Li-ion battery system has enabled the Antareselectric motor-glider to gain both altitude and range.

[email protected]

Self-launchingsailplane flieshigher and furtherwith Li-ion

propeller. After take-off and climb, the pilotsimply pulls a lever and the motor andpropeller retract into the fuselage for betteraerodynamics. The revolutionary craft canreach an altitude of 3,000 meters inpowered flight.

Light, powerful, compact and inthe wings

Lange’s design team decided on Saft MR(Medium Range) Li-ion cells, which packmaximum power into a lightweight, compactpackage. The cells have a nominal capacityof 41 Ah and a nominal voltage of 3.6 V,giving the glider a significant increase inpower from a much lighter battery. “We useSaft Li-ion batteries in this demanding appli-cation simply because we have found themto be the best on the market”, says CEO AxelLange. “The Antares demonstrator LF-20Eflew on Ni-MH batteries and performed well.But the extra power available when weswitched to the Saft Li-ion batteries hasenabled us to more than double the launch

Flying test bedLange recently won a contractfrom the German aerospace technology institute DLR to developa “flying test bed” for aviation fuelcells. The new Antares DLR-H2glider, built in 2008, is naturallypowered by Saft batteries.

height using a battery system that weighs26% less”.

The battery system comprises 72 cells in series, providing nominal voltage of 260 V.The total weight of the batteries, split intotwo customised packs in the inner wings, is about 80 kg, accounting for 12% of thecraft’s maximum take-off weight. Thebatteries are fitted with a dedicated elec-tronic management system to monitorcharge and discharge voltages, as well aselectrical heating to prevent the cold fromsapping the battery’s performance. Thesystem takes 8 hours to charge at 220 V

and the glider is fitted with its own chargerfor cross-country flights.

The Antares has been the leadingsailplane in its high-end segment for morethan four years now. Lange still has a longwaiting list of customers, most of whom areexport business. Proof of the quality of this“absolutely unique” glider, and of the relia-bility and long service-life (up to 20 years inthis application) of the Saft batteries thatpower it.


High-energy,high-reliability,low-weight Li-ion forRussia’s GEOsatellites

“This contract establishes Saft as animportant supplier for Russia’s largestcommercial satellite company”, says PhilippeJehanno, head of Saft’s Space & DefenceDivision. “It also consolidates our leadershipin state-of-the-art battery technology forcommercial GEO satellites”.

Saft’s contract with JSC ISS stems fromnegotiations begun in 2006, when JSC ISSdecided to develop a new competitive, highly-effective platform by using modern technolo-gies. “Both Saft and our Russian partner arewell-established players in our fields and wewanted a long-term relationship”, addsPhilippe Jehanno. “Our first challenge was tobridge the gap between our two cultures.Both top management and technical teamsnow see eye to eye and we are lookingforward to very fruitful synergies given thequality and level of our interaction”.

“The mass of a satellite’s storage battery

Saft has been chosen by Russia’sleading commercial satellite builder,JSC ISS-Reshetnev Company, to supplyLi-ion battery modules to power geo-stationary earth orbit (GEO) commercialsatellites based on its Express-1000Hplatform.

[email protected]

is half of the whole power system mass, soenhanced battery efficiency is a big plus inreducing the mass”, says AlexanderKorenko, Leading Design Engineer in the JSCISS Spacecraft Power Systems department."When we were looking for a Li-ion batteryspecialist, Saft was N°1 for energy efficiencyand battery life. Our specialists studied Saft’sproduction technology and certifications thenlooked at the development prospects of thecompany’s Li-ion technology for space appli-cations. Then we made our decision”.

Maximizing payload and revenue

Saft’s first order under this multi-optioncontract is to supply the battery system forthe AMOS-5 communications satellite nowunder construction for Israeli operatorSpacecom. Discussions are already under way

on subsequent Express-1000H spacecraft. The battery system for AMOS-5 will

comprise two modules consisting of 40 ofSaft’s latest generation VES 180 SA Li-ioncells. These cells, which have a nominalcapacity of 50 Ah, comply with all relevantESA standards and are designed to meet thespecific needs of today’s space projects,especially in terms of performance and relia-bility.

Thanks to their high specific energy of170 Wh/kg, made possible by Saft’sadvanced Li-ion technology, VES 180 SA cellsoffer weight savings of 30-50% comparedwith a conventional battery. This means JSCISS can dedicate more of the satellite’scritical mass to payload, which will help theoperator generate increased revenue.

Saft has signed a framework agreement with DCNS, Europe's leading player fornaval defence systems, strengthening their alliance in electrical energy storagetechnologies for naval applications. The main focus will be on submarines andtorpedoes.

Under this agreement, the two compa-nies will operate as a centre for innovativetechnologies covering electrical energystorage for all naval vessels includingfrigates, submarines, torpedoes andautonomous underwater or surface vehicles(AUV-ASV).

“Following years of ad hoc cooperation onenergy storage, our two companies will nowbe working together on a long-term basis”,says Philippe Jehanno, head of Saft’s Space& Defence division.

The new partnership is intended tocapture increased synergies. Saft focuses oninnovative energy storage technologies(batteries and accumulators) for industrialapplications. DCNS designs and builds navalvessels fitted with multiple systems (platformmanagement, propulsion, weapons, etc.)that involve very stringent technical require-ments. The optimisation of electrical energystorage is a key factor in the technicalperformance of these systems.

“DCNS is working right at the frontiers ofpropulsion technology and we wanted a long-term partner able to work at those frontierswith us”, says Jacques Mouysset, DCNSSenior Vice-President Strategy &Development. “We have been working withSaft for many years on a number of projectsand DCNS has been very satisfied with theircooperation and their products. We areconfident in Saft’s technological expertiseand above all their ability to develop innova-tive solutions”.

Innovative technologies

Closer cooperation will enable Saft andDCNS to make better technological andinvestment decisions at a very early stagebased on market developments and toincrease their competitive advantage.

The immediate focus will be to adaptinnovative Li-ion technologies to conventionalsubmarine propulsion and torpedoes, whileextending cooperation on AgO-Al batteriesfor torpedoes.

“Electric propulsion for surface navalvessels has strong potential but is still veryexperimental, and concrete projects aresome way off”, explains Jacques Mouysset.“Nevertheless, Saft’s ability to innovate willbe invaluable here. In the more immediatefuture, the main focus of our cooperation willbe torpedoes and submarines”.

Saft and DCNS have already seen veryfruitful cooperation in the field of torpedoespowered by seawater-activated AgO-Al

batteries. This should be a high-growth areain the next few years, and Saft is currentlyexpanding its production tool in Poitiers.

“Battery storage is crucial to submarinesand we think that Li-ion has a very importantrole to play”, adds Jacques Mouysset. “Themany advantages of Li-ion (lower weight,better endurance and higher energy densityper volume) give this technology a very signif-icant edge over other electro-chemistries,but we need to demonstrate that this tech-nology is a truly viable alternative to lead-acid.That’s where Saft’s know-how comes in”.

Naval propulsion systems:Li-ion goes to the next level

[email protected]


PARTNERSHIP


At Saft’s initiative, Europe’s ELU industryrecently organised an international summit inParis on the theme of “Ensuring reliability,quality and value”. The summit, held on 4-5December 2008 at the Hotel du Louvre inParis, brought together some 25 leadingELU players from all over Europe to identifyways to ensure quality, reliability and value inthe ELU or, in the words of one speaker “toensure that in future 100% of ELUs workwhen they have to”.

The starting point of the summit wasthe realisation that about 30% of ELUscurrently installed do not actually operatewhen needed, and that despite thenumerous applicable standards the units

are not checked as often as securitydevices should be.

The summit focus was on homologation,testing during installation, and annualchecking and maintenance on site.

Three corrective measures

Brainstorming sessions identified fiveareas for improvement and delegates set upan ELU Club du Louvre to implement anaction plan covering the 3 most urgentcorrective measures:• to persuade insurance companies to insiston annual checks and to include this in

[email protected]

Faced with anumber ofanomalies in theELU market, Safthas broughttogether themain Europeanplayers to identifyareas forimprovement andimplement anaction plan.

A European ELU Summitto enhance reliability,quality and value

building insurance contracts,• to push for mandatory ENEC labelling forall ELUs in Europe and ensure life-durationcriteria are met (ageing test),• to work towards an international/European standard equivalent to NFC 71830covering yearly checks, servicing and mainte-nance training.

Three working groups, two of them chairedby Saft personnel, were set up as a result ofthe summit and these groups will be meetingregularly to discuss the concrete details ofaction to be taken and to move the ideas intopractice.


PARTNERSHIP

Li-ion endurance and power forthe French Navy’s newmine hunter AUV

[email protected]

The state-of-the-art mine hunter AUV wasdeveloped and built for the Navy by the France-based robotic systems specialist ECA, whichhas worked with Saft for the last six years.

Safts advanced-technology Li-ion batterysystem, delivered at the end of 2008, enablesthe new AUV to stay submerged for longperiods and cruise at 4 knots (7.4 km/h). Li-ion is the only technology capable of providingthis combination of endurance and powerwithin the restricted space of the AUV’sdesign.

The 135V, 23 kWh battery systempowers both the propulsion and the electronicsystems of the Mine Warfare AUV. Thebattery system, based on Saft MP 176065Li-ion cells, is supplied as a fully-integrated andturnkey solution including mechanicalassembly, electronic control managementsystem for the monitoring of charge anddischarge voltages and cell temperatures, andEMC filtering.

Since 1960, ECA has designed and pro-duced more than 600 robotic vehicles (subseaand land-based) used for command & controlmissions, mine-detection/destruction, nuclearpower plant inspection, deep-offshore oil oper-ations, anti-terrorist missions, hazmat, etc.

A leading player

The “Guerre des Mines (Mine Warfare)”order followed the success of the identical Li-ionbattery system that Saft supplied for ECAsearlier Rapid Environment Assessment AUV,Daurade. “ECA has worked with Saft since2002 and chose the company’s Li-ion expertiseto equip its AUV range because this technologyis the best solution in terms of density, energy

Saft’s Li-ion technologyis now powering theFrench Navy’s latestAutonomous MineWarfare UnderwaterVehicle (AUV) during minedetection missions

and mass for this type of cell”, says ECA projectmanager Stéphane Meltzheim.

Saft is now emerging as a front runner inthe Unmanned Underwater Vehicle (UUV)segment. In early 2009 a third Li-ion batterysystem of this type was delivered to theASEMAR project, a partnership venturebetween Thales Underwater System SAS andECA and Saft (among others) to build UUVsfor civil applications such as oceanography,offshore oil and gas operations, surveillanceand Homeland Security. Saft Li-ion technologyis also powering the Redermor-3 experi-mental UUV platform developed by theFrench Navy’s research division GESMA.

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wireless tracking and communication systemby 2009.

MineTracer™ is the first system of thiskind to be approved by the US Departmentof Labor’s Mine Safety and HealthAdministration (MSHA). Because of the life-critical nature of the system, both theMineTracer™ and Saft’s batteries had toundergo very extensive testing before beingcertified to the very stringent US mine safetystandards.

Now that MSHA approval has been

obtained, tracking systems like MineTracer™should be installed very quickly. All under-ground coal mines in the United States musthave plans developed and submitted toMSHA by June 15, 2009 “We’ll besupplying the international market, too,” saysJim Barrett. “There’s a huge need for thistechnology in Europe, Africa, and China aswell.”

our Group’s partner companies such asHewlett-Packard”, adds Jim Barrett. “AndSaft was the only supplier of a Li-ion batteryapproved as IS by several other regulatoryagencies in the world. When we tested thesamples I was even more impressed, partic-ularly by the energy density. And we werepleased with Saft’s technical support whenwe were making our decision”.

Stringent certification criteria

Fatalities have often occurred after mineaccidents when rescue teams were unableto quickly locate and reach trapped miners.MineTracer™ was developed in response tothe Mine Improvement and New EmergencyResponse (MINER) Act passed by Congressin 2006, shortly after the mine disaster inSago (West Virginia). The MINER Actrequires all underground mines to operate a


Improved mine safety in the US thanks to Li-ion powered MineTracer™

tracking system With increased public awareness of mine safety,more underground mine operators are looking topersonnel-tracking systems to ensure that rescueteams will be able to locate miners who may betrapped or in trouble rapidly in the event of anaccident underground. A new system using Li-ionbattery back-up was the first to be approved bythe US government and is currently beingdeployed.

Venture Design Services, Inc. (VDSI) haschosen Saft’s intrinsically safe (IS) Li-ionbatteries to provide life-saving back-up powerfor its new mine emergency wirelesstracking and communication system.

MineTracer™, the first system of its kindavailable to mine operators, guides rescueteams straight to miners trapped under-ground after accidents. The Venture DesignServices system uses a wireless meshnetwork to provide real-time tracking of aworker’s location to within 75 feet. Minerscarry a personal location tag or a 2-way textdevice that communicates with WirelessAccess Points (WAP) which relay tracking

data and text between the miner and thesystem operator above ground.

The system normally operates on mainspower but during an emergency, power isusually shut off to reduce the risk ofmethane gas ignition, especially in collieries.Hence, emergency equipment must rely onbattery power. For MineTracer™, VDSIchose Saft’s single-cell, intrinsically safe MPbatteries, which are installed in the WAPsand each miner’s Text Communicator. The Li-ion batteries can power the system for atleast 48 hours after an accident.

Safer batteries for safer mines

“Our major requirement was an ISbattery”, says VDSI Engineering ManagerJim Barrett, “and I have long believed that Li-ion is the best technology in terms of mostkey battery characteristics - volume density,density vs mass, charge cycles, shelf life,etc.” Saft’s IS batteries are also designed tooperate in a potentially explosive atmos-phere.

“We chose Saft because they are highlyregarded and have experience with some of

[email protected]

Market leader

US-based VDSI, which has R&D facilities in

Washington and California, develops wire-

less communication products and systems

focusing on remote sensor networks and

data collection. The company, which

posted sales of $2.5 billion in 2008, is a

leading supplier of wireless communica-

tions systems like MineTracer™.


EVOLVING PLANET

[email protected]

Off-grid PV systems are on a roll,particularly non-domesticapplications, and new Ni-MHtechnology is set to take a significantshare of this market. Saft is wellplaced with its plug-and-play SmartVHT Modules.

Installed off-grid, non-domestic PV capacitywas estimated at 397 MW in 2007 and themarket is experiencing double digit growthper year. Typical applications here are irriga-tion, water supply, street lighting/signage,navigation aids, wireless LAN, weatherstations and environmental sensors, among

many others. Lead-acid storage batteriesdominate the market, but battery life andreliability are poor (meaning high replace-ment costs), environmental impact is a nega-tive factor and SLA technology does not copewell with PV conditions (high number ofshallow cycles, erratic charge rate and time,extreme temperatures).

Alternative energy storage for small PVsystems has not been widely avail-

able, particularly plug-and-playsolutions. Saft’s newSmart VHT Moduleswith their cutting-edgeNi-MH technology nowoffer an ideal solutionfor reliable, long-lifeand high-performanceenergy storage

Ni-MH: breakthroughtechnologyfor off-gridenergystorage

systems for small PV units. Saft’s Ni-MHelectro-chemistry compares favourably withSLA in terms of:• Performance (long life, failure resistance,temperature tolerance)• Total Cost of Ownership (over 20 years)• Integration of smart electronics(charge/discharge management, SOH,battery condition log)• Environmental profile (including ozonedepletion, energy depletion, air acidification,etc.).

Saft offers plug-and-play Smart Modules ina full range of solutions:• 12V, 24V, 36V in 10Ah increments• Other solutions available for integration withexisting PV controllers (1.1Ah, 2.0Ah, 4.0Ah,10Ah in various voltage configurations).

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NUMBER 25 SPRING 2009 SAFT - saftbatteries.com · NUMBER 25 SPRING 2009 SAFT INTERNATIONAL VISIT EXTREME POWER PAGE 10 Saft Lithium-ion batteries contribute to grid stabilisation