Background
A major electric utility in Japan is responsible for delivering stable power to millions of residents and businesses across the region. Uninterrupted power distribution depends on a reliable infrastructure and backup systems that activate during grid instability or outages. Reliable performance of these systems is essential to maintaining critical operations and avoiding disruptions.
To enhance the reliability and efficiency of its backup power systems, the utility implemented a wireless battery monitoring system. This system oversees the health and performance of uninterruptible power supplies (UPS) and DC power systems, which provide backup power for substations, control centers, and other critical infrastructure. The transition from manual monitoring to an automated solution aimed to improve operational efficiency, reduce maintenance costs, and enhance real-time visibility into battery health.
Challenge
Managing an extensive power infrastructure requires a reliable backup power strategy, particularly for substations and control systems that rely on UPS and DC power supplies. Historically, the utility relied on manual inspections to monitor battery performance, a process that was labor-intensive, time-consuming, and susceptible to human error.
Manual monitoring posed several challenges:
- Resource Constraints – Routine site visits required significant labor hours and logistical planning.
- Inconsistent Data Accuracy – Environmental factors and human error led to potential inconsistencies in battery assessments.
- Scheduled Maintenance Limitations – Failures were sometimes detected too late due to fixed maintenance schedules, increasing the risk of power disruptions.
To address these issues, the utility required a real-time, battery monitoring solution that would provide accurate health assessments, reduce reliance on manual inspections, and enable predictive maintenance.
Implementation
The utility deployed Franklin Electric Grid Solutions’ wireless battery monitoring system, designed to track key performance indicators such as voltage, temperature, and conductance. The system continuously assesses the state of health (SOH) of each battery, allowing maintenance teams to monitor and address potential issues before failures can occur.
The system combines real-time monitoring with a centralized software platform, issuing automatic alerts based on user-configured thresholds and generating reports to minimize site visits. This remote accessibility allows for more efficient resource allocation, enabling maintenance personnel to focus on critical tasks rather than scheduled inspections.
WITH THE BATTERY MONITORING SYSTEM THE UTILITY POWER SUBSTATION ACHIEVED:
Accurate State of Health Monitoring:
Real-time tracking of battery state-of-health through voltage, temperature, and conductance analysis supports proactive maintenance and prevent unexpected failures.
Easy Integration:
The system is fully scalable, allowing for future expansion across substations and control centers with reduced installation time, as the hardware communicates wirelessly with the base controller.
Operational Efficiency:
Battery monitoring enables remote diagnostics, reducing unnecessary site visits and allowing maintenance teams to address critical issues more effectively.
Data Accuracy & Predictive Maintenance:
Automated data collection eliminates human error, providing precise insights that support predictive maintenance strategies.
Conclusion
By transitioning from manual inspections to wireless battery monitoring, the utility has significantly improved the reliability and efficiency of its backup power infrastructure. The ability to track real-time battery health reduces operational costs, helps enable predictive maintenance, and ensures stable power delivery to millions of customers.
Improved battery visibility and reduced manual monitoring have enhanced the utility’s resilience against power disruptions. As the energy sector continues to evolve, intelligent battery management solutions will play a key role in maintaining reliable utility operations for the future.
